The amount of wear on the end face of the spot welding electrode and the amount of axial wear can reflect the degree of electrode wear during the spot welding process. In the electrode wear test of spot welding of pneumatic welding guns, axial wear is difficult to achieve on-line measurement. In the established servo welding torch spot welding test system, the servo welding gun encoder can accurately feedback and detect the axial displacement change information of the electrode.
The axial wear detection schematic diagram is shown in Fig. 7(a). The electrode initialization and wear detection procedures of the servo welding gun are run. By analyzing the electrode displacement change information of different welding stages fed back by the encoder, the axial wear of the electrode can be detected. After verification, the servo gun's axial displacement measurement accuracy is 10um, which fully meets the online detection requirements.
The specific axial wear detection results can be fed back in real time on the control panel. The result is shown in Figure 7(b). The axial wear method was tested by servo welding gun, and the electrode wear test was carried out according to the welding procedure specification of spot welding 0.8mmDP600. The axial wear characteristics of the new electrode and the polished electrode are shown in Fig. 7(c).
It can be seen that the wear rate in the initial stage of the electrode is significantly higher than that in the later stage. The wear rate of the new electrode in the initial stage (before 600 points) is 0.45 um/dot, and the later wear rate is 0.22 um/dot; the initial wear rate of the grinding electrode (before 600 o'clock) ) is 0.82 um / point, and the later wear rate is 0.35 um / point. Compared to the axial wear rate at the same wear moment, the grinding electrode is much higher than the new electrode.
It can be seen that the positional feedback characteristics of the servo welding gun can be used to detect the degree of axial wear of the electrode, to determine the degree of electrode wear and the quality of the grinding, and to provide a theoretical basis for electrode grinding and electrode replacement.
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