Digital welding machine for welding aluminum alloy parts of rail transit

Since 2003, our company has been developing and researching aluminum alloy components for subways. The products we have contracted are mainly aluminum alloy welded parts on subways and locomotives, including car body underframes, side walls, top covers and interior components. In particular, the end chassis is an important force component in the entire vehicle body, which requires a high quality grade of the weld, mainly using 5XXX series aluminum magnesium and 6XXX series aluminum magnesium silicon alloy. Such aluminum-magnesium alloys are prone to pores, cracks, softening of welded joints, etc., and the welding spatter is large, so the welding of aluminum-magnesium alloy is more difficult than carbon steel, and its welding characteristics are also different from steel.

We introduced these products with the FRONIUS welder of the TPS series by introducing the technology and experience of Siemens. At present, the welding machine is the main equipment for aluminum alloy welding of our company. It is the world's first digital welding machine with the following three advantages:
First, in terms of structure. Its volume and weight are the smallest in the world. The TPS4000 mainframe is only 35.2kg, with fault self-checking function, background setting menu function, energy saving and high efficiency (efficiency can reach 89%, power factor reaches 0.99, more than 50% energy saving than ordinary welding machine) , more than 25% energy saving than similar inverter welding machines).

Second, in terms of operation. The panel adopts intelligent design. In addition to the unified adjustment knob, other such as wire diameter selection, welding method selection, welding material selection, gas measurement, jog wire feeding, etc., all adopt light touch button design, which is convenient for welder operation. It does not affect the welder's visual experience and reduces misuse. The welding machine has 100 sets of welding expert specifications. When the welding wire diameter, material and base material thickness are input into the welding machine, the optimal welding parameters of the memory can be obtained. Reduced the requirements for welder expertise and reduced the workload of technicians.

Third, in terms of software optimization. In order to make the effect of the all-digital TPS welder MIG welding aluminum perfect, FRONIUS has further optimized the software, set up a welding aluminum expert specially used for aluminum alloy welding, and realize low-frequency coordinated pulse control by installing double-pulse software. The coordinated pulse frequency is up to 5 Hz. During the welding, the output energy and the wire feeding speed are synchronously pulsating, so that the molten pool vibrates accordingly, which is very favorable for the discharge of the air holes, and a fish skin scale weld with a very uniform appearance can be obtained.

At present, our company's welding machine uses this expert system when welding. In addition, the welding gun has the function of adjusting the welding parameters, and can store 100 sets of welding programs and functions such as droplet transfer status indication.

Although domestic welding technology has made great progress after nearly 30 years of rapid development, the true core welding technology is far behind the international famous brands. Although FRONIUS's TPS series of all-digital welding machines have been launched for 12 years, many domestic and foreign welding machine manufacturers have introduced fully digital MIG welding machines in recent years, but their expert system software for various aluminum alloy welding processes. It still needs to be improved. Therefore, most of the domestic MIG aluminum welding equipment can only be used for the welding of low-end aluminum products, and the welding of aluminum products with high quality requirements is also generally dependent on imported welding machines, such as FRONIUS MIG welding aluminum. The quality has reached the first-level requirements of the US military standard and can be used for the welding of high-grade pressure vessels.

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