Low spatter CO2 arc welding is often used for ultra-thin steel sheets with a thickness of under 1.0-mm. In this paper, a high speed forward and reverse motion control algorithm for the motor in a welding torch and a dedicated controller for it are presented. The dedicated controller is designed with a motor driver IC (A3930) and a DSP (TMS320F-28069) coded with the proposed motion control algorithm. It is easy to optimize the operating parameters in the proposed algorithm according to various thin steel sheets. Since the torch motor must be able to feed or retract welding wire at a high speed while cooperating with the brushed DC motor in the wire feeder, the performance required in selecting the torch motor is examined and presented in this paper. With the proposed control algorithm, an optimal torch motor and the developed controller, the feeding and retracting motions of the welding wire at high speeds are possible. This results in low heat inputs to the base material and low spatter short-circuiting transfer. To verify the superiority of CO2 arc welding with the proposed torch motor control algorithm and the developed controller, an arc welding robot prototype system was fabricated and 100% purity CO2 gas arc welding with thin steel plates with a thickness of 0.8-mm was performed. This was accomplished with an interlocking a 50 W class brushless DC motor as the torch motor, the developed low spatter motion controller and an arc welding power supply.

中文翻译：

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超薄钢板低飞溅CO2弧焊焊炬电机控制算法

低飞溅 CO2 电弧焊通常用于厚度小于 1.0 毫米的超薄钢板。在本文中，提出了一种用于焊枪电机的高速正反向运动控制算法及其专用控制器。专用控制器设计有一个电机驱动器 IC (A3930) 和一个用所提出的运动控制算法编码的 DSP (TMS320F-28069)。根据各种薄钢板，很容易优化所提出的算法中的操作参数。由于焊枪电机必须能够在与送丝机中的有刷直流电机配合的同时高速送入或收回焊丝，因此本文研究并介绍了选择焊枪电机所需的性能。使用所提出的控制算法、最佳割炬电机和开发的控制器，焊丝可以高速进给和退避。这导致对基材的低热量输入和低飞溅短路转移。为了验证采用所提出的焊炬电机控制算法和开发的控制器的 CO2 电弧焊的优越性，制造了电弧焊机器人原型系统，并使用 0.8 毫米厚的薄钢板进行了 100% 纯度的 CO2 气体电弧焊。这是通过互锁的 50 W 级无刷直流电机作为焊炬电机、开发的低飞溅运动控制器和弧焊电源来实现的。为了验证采用所提出的焊炬电机控制算法和开发的控制器的 CO2 电弧焊的优越性，制造了电弧焊机器人原型系统，并使用 0.8 毫米厚的薄钢板进行了 100% 纯度的 CO2 气体电弧焊。这是通过互锁的 50 W 级无刷直流电机作为焊炬电机、开发的低飞溅运动控制器和弧焊电源来实现的。为了验证采用所提出的焊炬电机控制算法和开发的控制器的 CO2 电弧焊的优越性，制造了电弧焊机器人原型系统，并使用 0.8 毫米厚的薄钢板进行了 100% 纯度的 CO2 气体电弧焊。这是通过互锁的 50 W 级无刷直流电机作为焊炬电机、开发的低飞溅运动控制器和弧焊电源来实现的。