1、Introduction of advantagein Submerged Arc Welding Technology 埋弧焊技术的优势介绍September 2008,The Next Generation in Submerged Arc Welding新一代的埋弧焊,The “State-of-the-Art” in Inverter Technology最先进的逆变焊机技术 Highest Capacity available on the Market市场上同类产品中最高的容量 High Efficiency Inverter高效率逆变焊机 WaveForm Control Tec
2、hnology波形控制技术 Greatest Control over the Welding Process焊接过程的最佳控制Solid State Switching Technology固态开关技术AC or DC Welding Processes交流或直流焊接工艺,The Next Generation in Submerged Arc Welding 新一代的埋弧焊,Market / Customer Demands 市场/客户需求Increased Production & Lower Costs 提高生产率、降低成本Increased Quality & Getting Sci
3、ence test data提高质量,提取科学的试验数据Higher Strength, Lower Weight Materials强度更高、重量更轻的材料Shorter Lead Times & Greater Flexibility 待工时间更短、灵活性更大,Fully Modular Inverter Type Power Source全模块化逆变型焊接电源 Single full range control at 100% duty cycle 100%暂载率单个全范围控制 Unlimited Paralleling 1000 amp Modules 无限并联1000安培模块 100
4、% software controlled 100% 软件控制 DC+, DC- and Variable AC frequency up to 100 HertzDC+, DC- 及最高达至100赫兹交流可变频率 Flexible Waveform Control灵活的波形控制 Variable AC Frequency可变交流频率 Independent Positive / Negative Levels独立的正、负波 Variable timing频宽可调,PowerWave AC/DC Power Source PowerWave AC/DC电源,CV, CC or Power Re
5、gulation Processes 平特性, 下降特性或功率调节技术Electronic phasing for multiple arc systems用于多弧焊系统的电子相位调整3-phase power factor corrected input三相功率因数校正输入 Arc performance independent of input power variations电弧特性不受输入电源变化影响Modular Components Controlled over Industry Standard DeviceNet and Ethernet Networks模块元件由基于工业标
6、准DeviceNet 和Ethnet网控制.,PowerWave AC/DC Power Source PowerWave AC/DC电源,Power Wave AC/DC 1000 Sub Arc “Single/Tandem Arc” System Power Wave AC/DC 1000 埋弧焊单丝/双丝系统,Power Feed 10SFC,Power Wave AC/DC 1000,Power Feed 10SFH,Arc Link - TCP/IP,All components communicate via a network using Arc Link over TCP/I
7、P Protocol 所有部件使用以TCP/IP协议的Arc link网络进行交流,Distributed System Architecture 系统分布结构,变位器控制和电源,送丝控制和电源,Clock Signal 时钟信号l,Ethernet,Wide Area Network Monitor Application 广域网络监视应用,Power Consumption电能消耗,How much is it going to cost?它的成本是多少？ Companys billing structure can have a significant impact on energy
8、costs公司的运行成本会随能源消耗的变化而发生重大变化。 Energy Cost (Normally KWh)电能消耗（通常的度数） Demand Charge (Normally Peak kVA)需求功率 Delivery Charges (Cost for proper cable sizing, fusing, equipment, etc. for electricity demand)电力传输成本（电缆尺寸，保险装置，设备等）,What is Power Factor?什么是功率因数,Associated only with AC Circuits只是针对交流电。 Simple
9、equipment such as light bulbs have a power factor of “1” meaning the AC current and AC voltages are perfectly aligned.简单的如电灯，它的功率因数是“1”，就意味它的电流和电压完全同步。 Power Factor = Real Power/Apparent Power功率因数实际功率/表观功率 High Power Factor a higher % of current drawn from the power line is used by the machine高功率因数意
10、味着有更高比例的有效电流被使用。 Poor Power Factor requires a higher current to be drawn to perform the same amount of work低功率因数意味着需更多的电流来完成相同数量的工作。,Power Triangle功率三角关系,P = V x I cosb (Real Input Power - kW)实际功率,S = V x I (Apparent Input Power - kVA)表观功率,Q=V x I sinb (Reactive Power -kVAR)无效功率,Power Factor 功率因数= c
11、osb,Advantages of High Power Factor 高功率因数的优势,Increased Power Supply Capacity增加电源容量 Minimizes size of electrical service necessary to supply the machines电力维修减小到最少。 Reduced Heat Load on Electrical Cables减少电缆线上的热损耗 Reduction of kVA Demand Decreases Electricity Delivery Charge需求功率的减少使得电力输送成本的减少 Reduced
12、Voltage Drop on Cables减少压降损耗 Improved Equipment Operation提高设备运行,Power Usage Comparison电源使用比较,WaveForm Control Technology 波形控制技术,Waveform Control Technology : Infinitely Variable AC 波形控制技术： 无限可变的交流,TIME时间,Current, Voltage or Power 电流,电压或电源,Negative负半周 Current Level电流水平= Deposition 熔敷率,Positive正半周 Cur
13、rent Level 电流水平 = Penetration熔深,Frequency频率,Cycle Balance周期平衡 = Penetration / Deposition 熔深/ 熔敷率,The waveform can be varied to control Penetration and Bead Shape变化波形可以控制熔深和焊道形状. Electrode Negative Deposition without the Arc Blow Concerns焊丝负半周熔敷无电弧偏吹 Arc to Arc interaction is controlled by Phase Shif
14、t Control. 电弧与电弧的干扰由相位转换控制,Effect of Wave Balance波形平衡的作用,70% DC POSITIVE DC+ PENETRATION熔深 = 0.387”,50% DC POSITIVE DC+ PENETRATION熔深 = 0.346”,30% DC POSITIVE DC+ 熔深 = 0.242”,Effect of DC Offset 直流偏差的影响,POSITIVE正极 = 835 Amps NEGATIVE负极 = 519 Amps PENETRATION熔深 = .366”,POSITIVE正极 = 450 Amps NEGATIVE负
15、极 = 822 Amps PENETRATION熔深 = .280”,PW AC/DC Pipemill Advantages PW AC/DC 运用在管道焊时的优势,More flexible to switch process parameters and run multiple wall thicknesses without physical changes更加灵活的焊接过程中的控制，可以焊接不同厚度的母材且不改变物理性能。 Change between 3-arc and 4-arcs as well as 4-arc to 5-arc operation seamlessly可以
16、平稳的从3弧转为4弧以及4弧转为5弧。 Different schedules are developed for each pipe size and simply downloaded into the welding machine针对不同的管道可以使用不同的程序，并且非常容易的下载到焊机上。 Technology normally allows to increase number of arcs by one more (i.e. 3 to 4 arcs ; 4 to 5 arcs)技术上一般允许在焊接中增加一个电弧（如3弧转为4弧以及4弧转为5弧）。,PW AC/DC Pipemi
17、ll Advantages PW AC/DC 运用在管道焊时的优势,Voltage and Current regulation is excellent - this allows running near the top end of the voltage range allowed by the procedure qualification极佳的电流电压调整可以在评定所允许的极限值上运行 The toe condition and reinforcement of the welds are very consistent均匀的焊脚和焊缝余高 Excellent Visual App
18、earance极佳的焊缝成形,Overview Recommendation for Fine Tuning Procedures推荐微调程序,Step 1:步骤1 Use DC+ Lead Arc前导电弧使用DC+ Use 50% Balanced and Symmetrical AC Trailing Arcs拖后电弧使用50%平衡且对称 Achieve Stable Operation and Confirm Installation确保运行稳定和安装正确 Step 2:步骤2 Increase Frequency on Trailing arcs to highest level wi
19、thout degrading beadshape or reducing current due to inductive effects (typically less than 90 Hz)增加拖后电弧的频率并保持焊道成形，或由于电感的影响而减小电流（一般少于90Hz）,Overview Recommendation for Fine Tuning Procedures推荐微调程序,Step 3:步骤3 Increase Voltage and Travel Speed together to maximize productivity增加电压和焊接速度以提高生产率 Adjust Cur
20、rent on Lead Arc to achieve penetration as required调整前导电弧的电流以提高熔深 Increase current on the trail arcs to increase deposition as required增加拖后电弧的电流以增加熔敷率 Step 4:步骤4 Add a small amount of DC- imbalance to AC waveforms and repeat step 3在交流波形上增加一点DC-分量，然后重复步骤3,Applications - Pressure Vessel 应用-压力容器,Deep G
21、roove Multi-Pass Welding深坡口多道焊 Two Arc AC-AC SAW Process双弧 AC-AC 埋弧弧工艺 165 mm Thick Plate 165 mm 厚板 62 Passes 62 道 30% increase in Travel speed30% 焊接速度的增加 23% Reduction in Heat Input 23% 热输入的减少,Spin Casting Application旋转铸件的应用 Casting molds are resurfaced with submerged arc 铸模用埋弧焊进行表面堆焊 Max. Mold Tem
22、p. 245 Deg. C模具最高温度 245 C 50 % increase in welding speed 焊接速度增加50 % Reduced rebuild time减少堆焊时间11 days to 6-7 days 11 天 到 6-7 天 $511,000 yearly cost reduction 年成本减少$511,000 $6 million reduction in Mold Stock模具库存量减少$6 million,应用:模具修复,Roll Formed and Welded管件成型和焊接 Trial System - April 2003 试用系统 - 2003年
23、4月28 Welding Stations 28 个焊接站Estimated 30,000 Man-hour Savings based on Trial System试用系统估计节约人力30,000 小时,Application : Offshore Structural应用:海洋平台结构,Tandem Sub Arc双丝埋弧焊 Typical DC-AC Deposition = 15 Kg/hr 典型的 DC-AC 熔敷率 = 15 Kg/hr AC-AC with 25% DC Pos. = 20 Kg/hr AC-AC 带 25% DC 正极 = 20 Kg/hr 35 % incr
24、ease in Production 生产率增加35 %,Application : Offshore Structural应用:海洋平台结构,Longitudinal Pipe Welding直缝管焊接 Conversion 3-Arc Welding to 4-Arc Welding 将3丝焊改为 to 4丝焊 1.7 m/m travel speed increased to 2.3 m/m 焊接速度从1.7 m/m增加到2.3 m/m No Change to Weld Bead Profile or Mechanical Properties焊缝形状和机械性能无改变 35% incr
25、ease in Production 生产率增加35%,应用:管道制造,Spiral Pipe Welding螺旋管焊接 DC-AC to AC-AC ID Weld DC-AC 改为 AC-AC 内焊 1.54 m/m to 1.90 m/m Travel Speed Increase 焊接速度从1.54 m/m增加到 1.90 m/m 23% increase in Production 生产率增加23% Excellent ID Bead Quality出色的内焊道质量,Application : Pipe Mills 应用:管道制造,Tandem Arc PF 10A User Int
26、erfaces双丝焊 PF 10A 用户接口Excellent Productivity Gains 30%出色的生产率提高30%,Application : Pipe Mills 应用:管道制造,New Welding Flux新焊剂 Designed to take advantage of Wave Form Control设计时充分利用波形控制的优点 Critical performance requirements重要的应用要求 Minimize undercut on ID weld减少内焊道的咬边 Wider, flatter bead profile焊道宽且平滑 No slag
27、 sticking 无粘渣 Robust for procedural variations参数变化小 Maintain mechanical properties机械性能一致 Lower Heat operation热输入小,Future Flux Improvements 将来焊剂的改进,Power Wave AC/DC 1000 Machine Overview,The Power Wave AC/DC machine can be broken down into two sub-assemblies (Powersource and AC-Switch) that are combi
28、ned to make the final assembly. These sub-assemblies are not sold separately.PW AC/DC 机器可以分成两部分（电源和AC开关箱），这两部分不单独出售The Powersource sub-assembly is the “upper portion” and is similar to the Power Wave 655. The powersources main function is to create a DC output.电源部分就是上半部分，和PW655相似。主要功能是DC输出。The AC-Sw
29、itch sub-assembly is the “lower portion” and is responsible for converting the Powersources DC output into an AC output. The AC-switch was designed with a removable “slide assembly”. This slide assembly contains all of the electrical components for simpler serviceability. AC开关箱就是下半部分，主要负责将DC转换成AC输出。
30、该开关箱设计成可移动的“滑动式装配”，包括了所有电气元件，以便于维修。,AC Switch AC开关箱,Power Wave AC/DC 1000,PW AC/DC 1000,PF-10A,Power Feed 10A Controller Power Feed 10A 控制箱,Power Feed 10A Controller Power Feed 10A 控制箱,Main User Interface for AC/DC Subarc Cell 焊接单元的主用户界面 Functionality Based on NA-5 and PF-10 功能主要基于NA5和 PF10 All Weld
31、 Parameters, Timers, Motion, Procedure Memory, Configuration, and Diagnostics are accessed at the PF-10A Controller所有的焊接参数，计时器，程序记忆，配置和故障诊断都需从该控制箱操作 Communicates using ArcLink 使用ArcLink通讯协议 Versatile Can Interface with Custom Controls and PLCs, Integrator Friendly, Multiple Configurations, easy Setu
32、p, etc通用性可以进行传统控制和PLC控制，教易集成，多重配置，容易安装，等,Layout布局,Dual Displays双重显示 Arc Indicator电弧指示 Dual Encoders双译码器 Status Light状态指示 Switch Panel控制板 Memory Panel存储板 Mode Select Panel 4模式选择板4 Infrared Port红外接口,Remote Pendant遥控器,See instructions in IM Manual for conversion转换详见操作手册,Functions功能,Six Procedure Memory
33、 Storage Locations六个程序存储单元 On-The-Fly Multi-Procedure Welding (same Mode)焊接中多程序转换（相同模式） ALL Procedure settings are Stored所有程序设置将被储存 Press Memory Button to Restore Parameters按下记忆键重新存储参数 Hold Memory Button for 2 seconds to Save按住记忆键保持2秒，存储操作完成 Memory Panel can be used to Set Limits存储板可以用作设定极限值,Functio
34、ns 功能,Digital Alpha Numeric Displays for Text Messaging文本信息数字化显示 SETUP Mode for additional Weld Parameters, Timers, Starting/Stopping Configuration, Diagnostics, etc “设置”模式是针对额外的焊接参数，计时器，起弧和熄弧设定，诊断等的设置 WELD MODE Procedure, Wire Size焊接模式程序，焊丝规格 AC CONTROL AC Parameters. AC控制交流参数 START OPTIONS Strike
35、and Start Parameters 开始选项起弧和开焊时参数 END OPTIONS - Crater and Burnback Parameters结束选项弧坑和回烧参数 IR PORT Wireless Communication 红外接口无线通讯,Weld Controls 焊接控制,Parameter must be set in SETUP MODE该虚线框内的数据必须在”设置”模式下设定,AC/DC Submerged Arc System AC/DC 埋弧焊系统,AC Wave Controls交流波形的控制 Frequency: The PW AC/DC can obta
36、in output frequencies up to 200Hz. The User Interface limits the range from 10Hz. To 100Hz.频率：该电源可以得到200Hz以下的输出频率。用户界面限定的范围为10100Hz。 Wave Balance: This variable refers to the amount of time the waveform spends in the DC+ part of the cycle 波形平衡：此变量是指一周期中交流波形的正半周所占时间。 DC Offset: This refers to the shi
37、ft of the peak current with respect to the zero crossingDC偏差：是指峰值电流相对于“0”坐标的偏差值。,Security安全,Lockouts停机 Must be enabled with PC or Palm Application必须通过PC或Palm来激活。 SETUP Menu设置菜单 “View Diags” “View Lockouts”,Security安全,Limits限制 Accessed on Memory Panel进入存储器 Press and hold any Memory Button until Limit
38、s menu comes up按下并按住存储钮直到限制设定菜单弹出 Press the Right MSP4 Button to access upper and lower range, use Knob to set values按下MSP4面板右边按钮进入上下限设定，用旋钮设定 Press Left MSP4 Button to exit parameter按MSP4面板左边按钮，退出。,Power Feed 10A Controller控制器,Single Arc Configuration单电弧配置,Electrode Sense Lead,Electrode Cable,Tande
39、m Arc Configuration双弧双电源,Electrode Sense Lead,Electrode Cables,Multi Arc Configuration多电弧配置,Electrode Sense Lead,Electrode cables,Subarc System Software & Communications 埋弧焊系统中的软件和通讯,ArcLink, DeviceNet, Ethernet Protocols,Overview总揽,Systems Software系统软件 Software Components软件组成 PC Applications应用软件 Co
40、mmunications通讯 Protocols协议 Subarc System埋弧焊系统,Communications通讯,Analog and digital communications.模拟和数字通讯 Role of communications in subarc systems.埋弧焊中通讯的作用 Advanced features for process monitoring.先进的焊接过程实时监视,Analog Calibration模拟校验,Analog circuitry may require calibration to ensure that the minimum
41、value (e.g, 0 ipm) is truly 0 volts and that the maximum value (e.g, 800 ipm) is truly 10 volts.模拟电路需进行校验，以确保最小值（例如:0 ipm）是真正的0伏，以及最大值（如：800 ipm)是真正的10伏。 Calibration is a maintenance item that must be done to ensure optimum performance.校验是维修的一项内容，以确保最佳性能 Re-calibration may be necessary if the power
42、source or robot is replaced.如果电源被更换后，需重新校验。,Cable Size电缆尺寸,Typically each analog and discrete signal requires a separate pair of wires resulting in large bulky cables.一般来说，每一模拟和离散信号需要一对单独的电线，从而增加电线的尺寸。,37 pin Analog/Discrete I/O Connector,Limited Access有限的访问,Access to information over the Analog/Dis
43、crete link is restricted to those circuits in the cable and is limited by the cable size.模拟连接的访问将受电缆尺寸等的限制。 All other adjustment and status information can only be accessed manually using the controls (knobs/displays) present on the machine.所有其他调整和状态信息只能通过手动来调整机器上的旋钮来完成。,Digital Communications数字通讯,N
44、o Calibration is required = Lower Maintenance!无需校验节省维修 Typically only two wires required for communications = Less Bulky Cables!只需两根线来完成通讯无需大容量电缆 All information is accessible = Supports Advanced Welding Processes.所有信息都可访问支持更先进的焊接过程 All information is accessible = Feature Upgrades Without New Hardwa
45、re!所有信息都可访问无需新的硬件就可进行功能升级,System Interface,PC,ArcLink,Ethernet,PF10A Controlled Systems PF10A 控制系统,PLC,System Interface,PC,DeviceNet,Ethernet,PLC Controlled Systems PLC 控制系统,Protocol Usage协议的使用,ArcLink. All boards internal to a power source talk over ArcLink. Control, feedhead, Ethernet gateway boar
46、ds as well as the Systems Interface and the PF10A.ArcLink：所有的PC板，控制板、送丝板、通讯板以及系统界面和PF10 ，在内部和电源之间的通讯都是通过它来完成。 DeviceNet. Only used in PLC controlled systems. Can connect each “Master” power source and the Systems Interface.Devicenet：只在PLC控制系统中使用。可以连接每一个主电源和系统的界面。 Ethernet. Required when paralleling
47、power sources. Optional use for PC tools.Ethernet：当有并联的电源时才使用。可以采用PC。,ArcLink,ArcLink is the leading digital communications protocol for the arc welding industry. ArcLink是焊接领域最领先的数字通讯协议。 ArcLink communicates in a pre-defined welding language.ArcLink通讯采用预定义的焊接语言。 The ArcLink cable includes enough pow
48、er to supply the MIG feeder.它的通讯线中有电源线，可以提供给MIG送丝机。 The ArcLink cable includes a torch voltage sense lead.ArcLink电缆中包括了焊枪上的电压反馈线。,ArcLink Advantages ArcLink的优势,Simpler cable system = Easy Installation!简单的电缆容易安装 Is Standard = Lower Cost! 标准件低成本 Highest performance robotic interface = Lowest Cycle Tim
49、e = More Parts per Day!高性能的机器人界面最短的周期时间每天生产更多的工件 Highest featured robotic interface = Greater Process Control! 高品质的机器人界面更好的过程控制,Ethernet以太网,Ethernet has been a networking standard for decades.以太网成为网络的标准已有几十年了 Ethernet provides the ability to to pull large amounts of information into monitoring and supervisory applications.以太网使得传送大量信息作为监视和追踪之用成为可能。 Ethernet interface cards and cables are readily available and are relatively inexpensive.以太网界面卡和电缆线比较容易得到并且相对便宜。,
