机器人弧焊系统基础培训

xxx,*,The future of welding is here.,*,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,xxx,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,xxx,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,上海林肯电气自动化部,机器人弧焊系统基础培训,Trainer,：,Maggie Mi,第一部分,机 器 人 弧 焊 系 统 的,基 本 介 绍,机器人焊接系统的,基 本 组 成,弧焊机器人,焊机,+,送丝机,焊枪及清枪装置,保护气体设备,工作台、工装夹具、变位机,安全系统（围栏、光栅、自动门、门 锁等）,排烟系统,其它配件等,发那科弧焊机器人简介,单机的组成,主要参数,发那科弧焊机器人种类,（,IB,系列）,Arc Mate 50iB_3L,标准轴数,: 6,轴,手臂负载,: 3kg,操作半径,: 856mm,重复精度：, 0.04mm,Old Series iB / M Robot,原,iB / M,系列机械手,Arc Mate 100iB/6S,M-6iB/6S,标准轴数,: 6,轴,手臂负载,: 6kg,操作半径,: 951mm,重复精度：, 0.08mm,Old Series iB / M Robot,原,iB / M,系列机械手,Arc Mate 100iB,M-6 iB,标准轴数,: 6,轴,手臂负载,: 6kg,操作半径,: 1373mm,重复精度：, 0.08mm,Old Series iB / M Robot,原,iB / M,系列机械手,Arc Mate 120iB,M-16 iB/20,标准轴数,: 6,轴,手臂负载,: 20kg,操作半径,: 1667mm,重复精度：, 0.08mm,Old Series iB / M Robot,原,iB /,系列机械手,Fanuc New Series iC / M Robot,发那科新,iC / M,系列机械手,Robot 机器人,Arc Mate 100iC,M-10iA,标准轴数,: 6,轴,手臂负载,: 10kg,操作半径,: 1420mm,重复精度：, 0.08mm,发那科弧焊机器人种类,（,IC,系列）,New Series iC / M Robot,新,iC / M,系列机械手,Arc Mate 100iC/6L,M-10iA/6L,标准轴数,: 6,轴,手臂负载,: 6kg,操作半径,: 1632mm,重复精度：, 0.10mm,New Series iC / M Robot,新,iC / M,系列机械手,Arc Mate 120iC,M-20iA,标准轴数,: 6,轴,手臂负载,: 20kg,操作半径,: 1811mm,重复精度：, 0.08mm,New Series iC / M Robot,新,iC / M,系列机械手,Arc Mate 120iC/10L,M-20iA/10L,标准轴数,: 6,轴,手臂负载,: 10kg,操作半径,: 2009mm,重复精度：, 0.10mm,New Series iC / M Robot,新,iC / M,系列机械手,R-J3iB/R-J3iC/R-30iA,B Cabinet Controller,B,型控制器,标准设计,提供,Arclink, Ethernet,接口,提供,PCMCIA,USB,接口,标准,ArcTool,软件包,可带,1-6,个外部轴,Robot controller机器人控制柜,R-30iA,A Cabinet Controller,A,型控制器,标准设计,提供,Arclink, Ethernet,接口,提供,PCMCIA,USB,接口,标准,ArcTool,软件包,可带,1-6,个外部轴,Robot controller,机器人控制柜,机器人控制器的结构,Structure of robot controller,机器人控制器的结构,Structure of robot controller,机器人控制器的结构,Structure of robot controller,Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Invertec CV350-R,适合材料,:,碳钢,焊接波型,: CV,电流范围,: 60-350A, 350A/60%,通讯方式：,ArcLink,逆变技术：,Inverter,（,30kHz),输入电源,: 380V/50Hz/3Phase/PE,经济实用,Power Wave F355i,适合材料,:,碳钢,/,不锈钢,/,合金钢,/,铝合金,焊接波型,: CV/Pulse/Rapid Arc/,Power Mode/Pulse on Pulse,电流范围,: 5-425A, 300A/100%, 350A/60%,波型控制技术：,Wave Control Technology,TM,通讯方式：,ArcLink,逆变技术：,Inverter,（,60kHz),全数字焊机,: Total Digital,输入电源,: 380V/50Hz/3Phase/PE,Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Power Wave i400,适合材料,:,碳钢,/,不锈钢,/,合金钢,/,铝合金,焊接波型,: CV/Pulse/Power Mode/Rapid Arc/,Pulse on Pulse/Total s,2,f,TM,电流范围,: 2-420A, 350A/100%, 400A/60%,波型控制技术：,Wave Control Technology,TM,通讯方式：,ArcLink,XT over Ethernet,高速逆变技术,: High Frequency Inverter,(120kHz),全数字焊机,: Total Digital,输入电源,: 380V/50Hz/3Phase/PE,Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Power Wave 455M Robotics,适合材料,:,碳钢,/,不锈钢,/,合金钢,/,铝合金,焊接波型,: CV/Pulse/Power Mode/Rapid Arc,/Pulse on Pulse/Tandem MIG,电流范围,: 5-570A, 450A/100%, 570A/60%,波型控制技术：,Wave Control Technology,TM,通讯方式：,ArcLink,逆变技术：,Inverter(60kHz),全数字焊机,: Total Digital,输入电源,: 380V/50Hz/3Phase/PE,Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Power Wave 455M/STT Robotics,适合材料,:,碳钢,/,不锈钢,/,合金钢,/,铝合金,焊接波型,: CV/STT/Pulse/Power Mode,Rapid Arc/Pulse on Pulse,电流范围,: 5-570A, 400A/100%, 500A/60%,波型控制技术：,Wave Control Technology,TM,通讯方式：,ArcLink,逆变技术：,Inverter(60kHz),全数字焊机,: Total Digital,输入电源,: 380V/50Hz/3Phase/PE,Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Power Wave 655 Robotics,适合材料,:,碳钢,/,不锈钢,/,合金钢,/,铝合金,焊接波型,: CV/Pulse/Power Mode/Rapid Arc,/Pulse on Pulse/Tandem MIG,电流范围,: 20-880A, 650A/100%, 880A/60%,波型控制技术：,Wave Control Technology,TM,通讯方式：,ArcLink,逆变技术：,Inverter(60kHz),全数字焊机,: Total Digital,输入电源,: 380V/50Hz/3Phase/PE,Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Power Feeder 10R,适合焊丝,:,实芯,/,药芯,/,铝焊丝,速度反馈装置，闭环精确控制。,四轮驱动，更换焊丝不需工具,通讯方式：,ArcLink,输入：,40V DC,送丝速度范围,: 50-800IPM(1.3-20.3m/min),70-1200IPM(2.0-30.5m/min),实芯焊丝范围,: .025-3/32 in (0.6-2.4mm),.025-1/16 in (0.6-1.6mm),药芯焊丝范围：,.035-.120 in. (0.9-3.0mm),.035-5/64 in (0.9-2.0mm),Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Auto Drive 4R90,适合焊丝,:,实芯,/,药芯,/,铝焊丝,速度反馈装置，闭环精确控制。,四轮驱动，更换焊丝不需工具,通讯方式：,ArcLink,输入：,40V DC,送丝速度范围,: 50-800IPM(1.3-20.3m/min),实芯焊丝范围,: .023 - .045 in. (0.6 - 1.2 mm),药芯焊丝范围：,.035 - .045 in. (0.9 - 1.2mm),Lincoln Robotics Power Sources and Feeder,林肯电气机器人焊接电源和送丝机构,Tregaskiss Torch,特雷克斯焊枪,Tough Gun,Through Arm Tough Gun,Torch Cleaning Station,Binzel Torch,宾采尔焊枪,Binzel 35KD,Binzel ROBO A360,Through Arm A500,BRS-CC,Torch and Clean Station,焊枪及清枪装置,Tregaskiss Air Cooler Robotics Torch for iB Robot,特雷克斯空冷,iB,机器人焊枪,Tough Gun 500A (,泰霸）,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.6mm,电流,: 500A/100%/CO2, 350A/100%/Ar,混合气,焊枪角度：,22,，,45, 180,Torch and Clean Station,焊枪及清枪装置,Tregaskiss Air Cooler Robotics Torch for iB Robot,特雷克斯空冷,iB,机器人焊枪,Torch and Clean Station,焊枪及清枪装置,Tregaskiss Air Cooler Robotics Torch for iC Robot,特雷克斯空冷,iC,机器人焊枪,Through Arm Tough Gun 500A (,泰霸）,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.6mm,电流,: 500A/100%/CO2, 350A/100%/Ar,混合气,焊枪角度：,22,，,45, 180,Torch and Clean Station,焊枪及清枪装置,Tregaskiss Robotics Torch Clean Station,特雷克斯机器人清枪站,标准型,清枪装置,喷硅油,/,防飞溅装置,剪焊丝装置,适用所有,Tregaskiss,焊枪系列,Torch and Clean Station,焊枪及清枪装置,Binzel Air Cooler Robotics Torch for iB Robot,宾采尔空冷,iB,机器人焊枪,ABIROB 350GC,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.2mm,电流,: 350A/100%/CO2, 300A/100%/Ar,混合气,焊枪角度：,30,，,35,经济型,ABIROB A360,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.4mm,电流,: 360A/100%/CO2, 290A/100%/Ar,混合气,焊枪角度：,22,，,45,，,180,ABIROB A500,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.6mm,电流,: 500A/100%/CO2, 370A/100%/Ar,混合气,焊枪角度：,22,，,45,，,180,Torch and Clean Station,焊枪及清枪装置,Binzel Air Cooler Robotics Torch for iC Robot,宾采尔空冷,iC,机器人焊枪,ABIROB 350GC ECO,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.2mm,电流,: 350A/100%/CO2, 300A/100%/Ar,混合气,焊枪角度：,30,，,35,经济型,ABIROB A360,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.4mm,电流,: 360A/100%/CO2, 290A/100%/Ar,混合气,焊枪角度：,22,，,45,，,180,ABIROB A500,焊丝,:,碳钢,/,不锈钢，实芯,/,药芯, 0.8-1.6mm,电流,: 500A/100%/CO2, 370A/100%/Ar,混合气,焊枪角度：,22,，,45,，,180,Torch and Clean Station,焊枪及清枪装置,Binzel Robotics Torch Clean Station,宾采尔机器人清枪站,BRS-CC,1.,清枪装置,2.,喷硅油,/,防飞溅装置,3.,剪焊丝装置,适用所有,Binzel,焊枪系列,Torch and Clean Station,焊枪及清枪装置,Shield Gas Pipeline,供气系统管路,Shield Gas and Peripheral,保护气体及辅助设备,Flow Meter,流量计,Flow Control Valve,流量计控制阀,Shielding Gas Hose,保护气气管,Hand Wheel,手轮,Cylinder Valve,气瓶阀门,Shielding Gas Cylinder,保护气气瓶,Cylinder Pressure Gauge,气瓶压力表,Shield Gas Bottle,气瓶,Shield Gas and Peripheral,保护气体及辅助设备,Work table and safety guards,工作台及安全系统,Fume extraction,排烟系统,PMC Controller in,Robot,机器人内,PMC,控制器,PLC Controller,控制器,(Omron/SIMENS,）,Power Supply,电源,Electrical Cabinet,电气柜,Light Beacon,指示灯,Push Buttons,按钮盒,HMI and Control System,人机界面和控制系统,设备间的集成、通讯及系统的控制,连接及通讯,控制工具（示教器）,主要接线及控制,主要接线及控制,系统操作工具,机器人示教器（,TP,）,作用：,点动机器人,编写及运行机器人程序,查阅机器人状态,进行一切设置,R-J3iB,示教器结构,RESET,键,（复位键）,:,按此键清除报警信息。,TEACH,SHIFT,键,:,与其他键配合使用执行特定功能。,TEACH,Jog,键,:,使用这些键来点动机器人。,J1,J2,J3,J5,J4,J6,TEACH,COORD,键,:,用该键来切换机器人运动的坐标系,（,World,Tool,Joint),J1,J2,J3,J5,J4,J6,TEACH,+ X,- X,-Y,+Y,+Z,- Z,+ X,+Y,+Z,机器人坐标系,关节坐标系（,Joint,）,直角坐标系（,World,）,工具坐标系（,Tool,）,其它坐标系,速度键,:,用这些键来调整机器人的运动速度。,TEACH,程序键,:,用这些键来选择编程时的菜单选项。,SELECT,键,显示程序清单,EDIT,键,显示当前使用或编写的程序,DATA,键,显示,weld schedules, weld processes, weave schedules, TorchMate data,等,TEACH,功能键,:,使用这些键根据屏幕显示执行指定的功能和操作。,F1 key,F2 key,F3 key,F4 key,F5 key,TEACH,NEXT,键,:,按下该键显示更多的对应于,F1-F2-F3-F4-F5,按键的功能键。,TEACH,光标键,:,使用这些键在屏幕上按一定的方向移动光标。,TEACH,数字键,:,这些键用来输入数值,:,0, 1, 2, 3, 4, 5, 6, 7, 8, 9,减号,(-),小数点,(.),逗号,(,),TEACH,确认键,:,使用该键确认一个数值的输入，或者从一个菜单中确认选择一个项目。,TEACH,STEP,键,:,在,T1,或,T2,模式中,使用该键在以下两种执行模式间切换：,单步模式,(,每次执行程序中的一行,),连续模式,(,连续运行程序）,TEACH,在屏幕顶端有状态显示表明,STEP,键是否开启,:,FWD (,前进,),键,:,在,STEP,开启时使用该键来执行下一个程序语句。,连续运行程序时，使用该键驱使机器人开始执行编好的程序。,TEACH,BWD (,后退,),键,:,用该键执行排在光标前面的程序语句。,TEACH,WELD ENBL,键,:,运行一个程序时，使用该键来控制是否开启焊接过程,TEACH,有状态显示模式来显示是否启用了,Weld Enabled:,焊丝运动键,:,Wire “+”,使焊丝经由焊枪送出,Wire “”,使焊丝经由焊枪回抽,TEACH,ITEM,键,:,用该键 在一个列表中选择一个项目,TEACH,要在一个,TP,程序列表中选择一行,按下,ITEM,输入要选行的编号后按下,ENTER,例,:,1.,要在一个,System Variables,清单中选择一行，按下,ITEM,键，输入要选行的编号后按下,ENTER,2.,BACK SPACE,键,:,使用该键能依次删除光标前的字母和数字,TEACH,. JOINT 10%,1 Words,2 Upper Case,3 Lower Case,4 Options -Insert-.,-Create Teach Pendant Program,- -Program Name Testm6,6, .,PRG MAIN SUB TEST,PREV,键,:,用该键能显示上一级屏幕界面,TEACH,FILE JOINT 10%,61276 bytes free 2/4,No Program name Comment,1 SAMPLE1 SAMPLEPRG1,2 SAMPLE2 SAMPLEPRG2,3 TEST1 TESTPRG1,4 TEST2 TESTPRG2,TYPE,CREATE,DELETE COPY,F1 F2 F3 F4 F5,. JOINT 10%,1 Words,2 Upper Case,3 Lower Case,4 Options -Insert-.,-Create Teach Pendant Program,- -Program Name .,PRG MAIN SUB TEST,CREAT PREV,MENUS,键,:,用该键显示菜单屏幕：,TEACH,下面是按下,MENUS,后出现的列表,:,1.UTILITIES ,2.TEST CYCLE ,3.MANUAL FCTNS ,4.ALARM ,5.I/O ,6.SETUP ,7.FILE ,8.USER,9.SELECT,10.EDIT,11.DATA ,12.STATUS ,13.POSITION,14.SYSTEM ,15.BROWSER,HOLD,键,:,用该键可停止机器人的运动,TEACH,FCTN,键,:,用该键显示补充菜单,TEACH,按下,FCTN,键后出现的典型项目：,ABORT (ALL),Disable FWD/BWD,CHANGE GROUP,QUICK/FULL MENUS,SAVE,PRINT SCREEN,etc. . .,R-J3iB,示教器,状态指示区,:,显示系统当前状态,TEACH,Diag/Help,键,:,按下该键可以获得,1,、关于如何使用当前屏幕的信息,2,、使用,DIAGnostics,键显示如下信息：报警信息说明、起因和纠正办法,TEACH,POSN,键,:,按下该键显示要查找的位置信息,.,JOINT 10%,J1= deg J2= deg,J3 = deg J4 = deg,J5 = deg J6 = deg,TEACH,STATUS,键,:,按下该键显示机器人当前的焊接状态值。,TEACH,MOVE MENU,键,:,按下该键，会出现系统宏程序的列表，可执行宏程序的调用,TEACH,MAN FCTN,键,:,按该键显示手动操作功能屏幕,TEACH,Display,键,:,该键与,SHIFT,键一起使用，改变屏幕显示格式，从单对话框转换到双对话框或三对话框格式、单对话框带扩展状态。,操作机器人注意事项,1.,示教和手动机器人时：,1,）请不要带手套操作示教盘和操作面板。,2,）在点动操作机器人时要采用较低的倍率速度以增加对机器人的控制机会。,3,）在按下示教盘上的点动键之前要考虑到机器人的运动趋势。,4,）要预先考虑好避让机器人的运动轨迹，并确认该线路不受干涉。,2.,生产运行时：,1,）在开机运行前，须知道机器人根据所编程序将要执行的全部任务。,2,）须知道所有会左右机器人移动的开关、传感器和控制信号的位置和状态。,3,）必须知道机器人控制器和外围控制设备上的紧急停止按钮的位置，准备在紧急情况下按这些按钮。,4,）永远不要认为机器人没有移动其程序就已经完成。因为这时机器人很有可能是在等待让它继续移动的输入信号。,上机实践操作,熟悉如何上电开机,熟悉示教器的各按键,熟悉机器人的运动,掌握,TCP,的建立方法,第二部分,程序的选用、创建及编写,选择及创建程序名,选用已创建的焊接程序,(Select,）,为新建焊接程序创建程,序名,（,F2 Create-,输入程序名,）,FILE JOINT 10%,61276 bytes free 2/4,No Program name Comment,1 SAMPLE1 SAMPLEPRG1,2 SAMPLE2 SAMPLEPRG2,3 TEST1 TESTPRG1,4 TEST2 TESTPRG2,TYPE,CREATE,DELETE,COPY,F1 F2 F3 F4 F5,. JOINT 10%,1 Words,2 Upper Case,3 Lower Case,4 Options -Insert-.,-Create Teach Pendant Program,- -Program Name .,PRG MAIN SUB TEST,程序的详细设置,Program Detail JOINT 10%,5/10,Create Date: 10-MAR-1994,Modification Date: 10-MAR-1994,Copy source *,Positions: FALSE Size: 312Byte,1 Program name: SAMPLE2 ,2 Sub Type: None ,3 Comment: *,Group Mask: 1,*,*,*,* ,4 Write protection: OFF ,5 Ignore pause: OFF ,END PREV NEXT,按,F,键对应的,detail,功能， 出现下方程序详细设置界面。,主要用在对有外部轴的系统进行设置。,三个基本 “点”,零位（,Zero,Position,）,JP,1,100% FINE,自行将,P,1,点,joint,坐标值全部改成,0,度。然后运行该程序，机器人自动恢复到,0,点位置上。,SAFEHOME,点,1. JP 1 100% FINE,自己定义,P 1,点的位置并作为系统运行的安全点,工具坐标系原点,( TCP),机 器 人 的,三种运动轨迹及表示方法,点对点运动（,Joint- J,）,直线运动 （,Linear-L,）,圆弧运动 （,Circle-C,）,上海林肯电气自动化,精确到位,FINE,圆滑过渡,CNT,Robot Program Movement End types,机器人编程运动结束方式,典型焊接程序的编写,（,EDIT,）,直线轨迹的焊缝焊接程序,圆弧状轨迹的焊缝焊接程序,直 线 焊 接 的 编 程,1. JP 1 100% FINE,2. JP 2 100% CNT100,3. LP3 100mm/sec FINE,Arc Start1,4. LP4 20mm/sec FINE,Arc End1,5. JP5 50% CNT100,6. JP6 50% CNT100,7. Call SafeHome,Point Arcstart Weld_ PT Arcend Touch Up ,F1 F2 F3 F4 F5,圆 弧 焊 接 编 程,1. JP1 100% FINE,2. JP2 100% FINE,3. LP3 500mm/sec FINE,Arc Start1,4. CP4,P5100mm/sec FINE,5. CP6,P7 100mm/sec FINE,Arc End1,6. JP8 100% FINE,7. Call SafeHome,Point Arcstart Weld_ PT Arcend Touch Up ,F1 F2 F3 F4 F5,编程时常用的,中高级指令及功能,EDCMD (F5),（,Insert, Delete, Copy, Paste, Undo,）,INST (F1),( Program control, arc start/end, timer, wait, Weaving, IF,JMP,PR,R, Offset, DO,DI),EDCMD,类操作指令,1. JP1 100%,fine,2.,JP2 100%,fine,3.,LP3 100%,fine,INST EDCMD,Insert, Delete, Copy, Paste,Replace, Renumber, Undo,F1,F5,INST,类操作指令,1. JP1 100%,fine,2.,JP2 100%,fine,3.,Arc start1,4.,LP3 100%,fine,INST EDCMD ,Program control,2,. Arc start/end,3. Timer 4. Wait,5. Weaving,6. IF/JMP,7. PR 8. Next page,F1,F5,要点的复习,创建新程序,直线和圆弧程序的编写,程序中各术语的灵活运用和修改,上机实践,第三部分,焊接基础及参数的设置,Welding Concept:,焊接原理,:,-,Welding is a process which can join two or more pieces of same materials or different materials together by an atom or molecular level diffused connection.,-,焊接是,两种,或,两种以上,的,同种,或,异种材料,通过原子或分子之间的,结合,和,扩散,而连接成一体的工艺过程,Welding Joint Concept,焊接接头概念：,Joint produced by welding and consisting of a weld,，,a weld line (only present if the metal is fused),，,heat-affected zone and non-affected parent metal.,焊接接头是采用焊接工艺形成的不可拆卸的连接接头。它由焊缝、熔合线（区）、热影响区及其邻近的母材组成。,1.SMAW:,手工电弧焊,2.GMAW,：,用外加气体作为电弧介质并保护,电弧和焊接区的电弧焊。,3. GTAW:,钨极氩弧焊,4. FCAW,：,药芯焊丝气体保护焊,5. SAW,：,埋弧焊,五种主要的焊接方法,Theory:,An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool to produce a fusion (melting) together of the base metal. The process is used with a shielding gas (or gas mixture) from an externally supplied source and without the application of pressure.,原理：,采用电弧,(,在持续送进的可熔化焊丝和被焊工件之间形成的,),做为热源来熔化焊丝和母材金属并形成熔池与焊缝的焊接方法，最终达到母材熔合的目的。该焊接方法要使用外供保护气体或混合气体。,GMAW Basic,熔化极气体保护焊基础,实心焊丝,保护气体,正极导电电缆,凝固的焊缝金属,焊丝导管和导电嘴,气体喷嘴,保护气体,电弧,工件,熔化的,焊缝金属,GMAW Basic,熔化极气体保护焊基础,Advantages,优点,Popular Welding Process,流行的焊接工艺,Simple,简易,Clean,清洁,Low Cost,低成本,Wide Variety of Material Types,可焊材料种类多,Wide Variety of Thicknesses,可焊厚度范围大,Deposits Low Hydrogen Welds,焊缝氢含量低,High Efficiency Applications,焊接效率高,Little to No Slag,很少甚至没有焊渣。,GMAW Basic,熔化极气体保护焊基础,Limitation,局限性,Portability (Shielding Gas Cylinder & Hoses Required),可携带性差（气瓶，气管）。,Outdoor Welding (Shielding Gas is Susceptible to Wind & Drafts),不易在户外焊接（保护气体易受外部气流的影响）。,Requires Base Material To Be Clean (Free of Dirt, Oxide and Oils),焊接母材需要清理干净。,Potential for Cold Lap in Short Circuit (Metal) Transfer,短路过渡易产生未焊透和冷隔缺陷。,Potential for Undercut in Spray Arc (Metal) Transfer,喷射过渡易产生咬边缺陷。,A Moderate Level of Operator Skill Necessary,需要中等焊工技能。,GMAW Basic,熔化极气体保护焊基础,GMAW Classify,分类 ：,MAGC,GMAW Basic,熔化极气体保护焊基础,Modes of Metal Transfer,熔滴过渡形式,Short-Circuit Metal Transfer,短路过渡,Globular Transfer,滴状过渡,Spray Transfer,轴喷射过渡,Pulsed Spray Transfer,脉冲喷射过渡,Surface Tension Transfer,表面张力过渡,GMAW Basic,熔化极气体保护焊基础,Short Arc Transfer,短路过渡,-,当进行焊接时采用小的焊接规范（低电弧电压，小焊接电流）因弧长较短（,2-3mm,），焊丝末端形成的熔滴在尚未充分长大，且未脱落时便与熔池表面接触，形成电弧两极的短路，在电磁力，熔滴重力和表面张力等作用下，使熔滴迅速溶入熔池的过程,GMAW Basic,熔化极气体保护焊基础,Arc Initiated,起弧,Droplet Forms,熔滴形成,Droplet Shorted,短路,Metal Transfers,过渡,Fuse Forms,缩颈形成,Fusing Event,熔断,Arc Re-established,二次起弧,Short Arc Transfer,短路过渡,Advantages,优势,Low Heat Input,低热输入,All Position Welding,全位置焊接,Low Cost,低成本,Handles Poor Fit Up,对坡口装配要求低,Limitations,局限性,Spatter,飞溅,Potential Lack of Fusion,易未熔合,Limited to Thin Material,焊接较薄的母材,Short Arc Transfer,短路过渡,影响短路过渡稳定的主要因素 ：,a,）电弧电压,b,）焊丝直径,c,）送丝速度,0,20,30,10,50,100,150,0.8,1.0,1.2,电弧电压（,V),短,路,频,率,（,N/s),电弧电压对短路过渡的影响,0,300,500,100,20,60,100,1.0,短,路,频,率,（,N/s),送丝速度（,cm/min,）,送丝速度对短路过渡的影响,Short Arc Transfer,短路过渡,When to Use,何时使用,:,Low Voltages,低电压,( 16V To 22V ),Low Amperages,低电流,( 30A To 200A ),Wire Electrode Size,焊丝尺寸,:,Typically Smaller Diameters ( 0.025 in To 0.045 in ),细焊丝,( .60 mm To 1.20 mm ),Shielding Gases Used,保护气体使用,:,100% CO,2,Gas (Lowest Cost,低成本,Big penetration,大熔深,),75% Ar/25% CO,2,Gas Mix,混合气,Short Arc Transfer,短路过渡,Globular Transfer,滴状过渡,-,当进行焊接时采用中等焊接规范（较高电弧电压，较大焊接电流）因弧长较长（,5mm,），焊丝末端形成的熔滴得以充分长大，在熔滴过渡诸力的作用下，脱落的熔滴经过电弧空间而落入熔池的过程,a,、电弧燃烧熔滴渐成,b,、斑点压力熔滴横长,c,、熔滴爆断电弧波动,d,、滴入熔池电弧变短,f,、熔滴沉入弧长恢复,滴状过渡形成示意图,Arc Initiated,起弧,Large Droplet Formations,低大熔滴形成,High Amperage (Arc Spot Location),电流增大,Gravity Often Pulls the Droplet Off Non-axially,在重力下坠落,Deposition Occurs Out of the Weld Pool,可能会在熔池外,Spatter Forms Aroundthe Weld,在焊缝外会有较多的飞溅,Globular Transfer,滴状过渡,Advantages,优势,Deep Penetration,熔深大,High Deposition,熔敷率高,Low Cost Gas,气体成本低,Limitations,局限性,Excessive Spatter,飞溅多,Flat / Horizontal Position Only,只能平焊,/,横焊位置,Globular Transfer,滴状过渡,When to Use,何时使用,:,High Voltage,高电压,( 25V To 35V),High Amperages,高电流,( 200A To 500A ),Wire Electrode Size,焊丝尺寸,:,Typically Larger Diameters (0.035 in And Larger),一般使用较粗的焊丝,(1 .0 mm And Larger),Shielding Gases Used,保护气体,:,100% CO,2,Gas Mix (Lowest Cost,低成本,),75% Ar/25% CO,2,Gas Mix,混合气,Globular Transfer,滴状过渡,Spray Transfer,射流过渡,-,当进行焊接时在大熔滴过渡的基础上再增大焊接电流使得焊丝熔化速度增大增强，而熔滴的粒度反而变小，熔滴过渡的频率加快，当电流增大到一定程度时，熔滴过渡变成射流过渡,射流过渡形成示意图,a,、电弧燃烧丝断即熔,b,、电磁力强细滴速成,c,、沿弧中轴 细滴如流,d,、穿过电弧注入熔池,f,、熔滴连注电弧稳定,Arc Initiated,起弧,Amperage Above the Transition Level,电流大于一定值,Point Forms on End of Electrode Wire,熔滴在焊丝端部产生,Fine Sub-diameter Droplets Are Directed Axially From the Wire to Weld Pool,当熔滴还未变大时就直接从焊丝端部喷射到熔池中。,Only True “Through the Arc” Transfer,是真正的通过电弧过渡,Spray Transfer,射流过渡,Advantages,优势,Smooth Weld Bead,焊道成形好,Deep Penetration,熔深深,High Deposition,熔敷率高,Little to No Spatter,飞溅少或没有,Limitations,局限性,Potential Undercut,易咬边,Higher Shielding Gas Cost,保护气体成本高,Flat / Horizontal Position Only,平焊,/,横焊焊接,High Radiated Heat,高辐射热,Spray Transfer,射流过渡,When to Use,何时使用,:,High Voltages,高电压,( 25V To 35V ),High Amperages,高电流,( 200A To 500A ),Wire Electrode Size,焊丝尺寸,:,Typical Wire Diameters (0.045