In the welding of thin plates, due to the small thickness and weak rigidity of the material, localized thermal expansion caused by welding heat input easily leads to compressive plastic deformation under rigid constraints, resulting in problems such as wavy deformation and angular deformation. Automatic soldering machines, through integrated force control technology, can monitor and adjust parameters such as welding pressure and current in real time during the welding process, effectively suppressing thin plate deformation. Its core implementation path encompasses multiple aspects, including mechanical structure design, sensor feedback, control algorithm optimization, and coordinated adjustment of process parameters.
At the mechanical structure design level, the welding torch or welding head of an automatic soldering machine is typically equipped with a high-precision pressure sensor and a displacement adjustment mechanism. The pressure sensor can sense the contact pressure between the welding torch and the thin plate in real time and transmit the signal to the control system; the displacement adjustment mechanism dynamically adjusts the position of the welding torch according to control commands to ensure stable pressure during the welding process. For example, when the sensor detects an abnormal increase in pressure, the system determines that it is due to localized thermal expansion of the thin plate and then adjusts the height or angle of the welding torch to reduce localized pressure concentration and avoid deformation caused by excessive compression.
The sensor feedback system is the core data source for force control technology. In addition to pressure sensors, automatic soldering machines can integrate current, voltage, and vision sensors to form a multi-dimensional monitoring network. Current and voltage sensors reflect the real-time intensity of the welding heat input. Combined with pressure data, the system can determine whether the welding area is softening due to excessive heat input, and then adjust the welding speed or current parameters to control the heat-affected zone. Vision sensors monitor the weld formation state through image recognition technology. If abnormal weld width or surface ripples are detected, the system immediately corrects the welding trajectory or pressure parameters to prevent further deformation.
Optimization of the control algorithm is key to achieving deformation suppression in force control technology. Automatic soldering machines typically employ a closed-loop control strategy, using pressure sensor feedback as input and dynamically adjusting welding parameters through PID control or fuzzy control algorithms. For example, when welding butt joints of thin plates, the system adjusts the wire feed speed and welding current based on real-time pressure data to ensure stable weld pool dimensions, preventing burn-through due to an excessively large weld pool or incomplete fusion defects due to an insufficiently small weld pool. Simultaneously, the algorithm combines welding speed and pressure variation trends to predict deformation risks and intervene in advance. For example, when welding to the edge of a thin plate, the system automatically reduces pressure and slows down the welding speed to prevent wavy deformation caused by stress concentration at the edge.
The coordinated adjustment of process parameters reflects the deep integration of force control technology and welding processes. Automatic soldering machines can preset multiple sets of welding parameter libraries based on the characteristics of thin plate materials (such as carbon steel, stainless steel, and aluminum alloy) and thickness, and dynamically switch parameters during welding based on force control feedback. For example, when welding thin aluminum alloy plates, because aluminum alloys have high thermal conductivity and are easily deformed, the system will prioritize low-heat input parameters and adjust the welding pressure in real time through force control technology to ensure uniform heating of the molten pool and the thin plate contact surface, avoiding deformation caused by local overheating. Furthermore, the system can optimize pressure distribution based on weld type (such as fillet welds and butt welds). For example, when welding fillet welds, by adjusting the welding torch angle and pressure, the thin plates on both sides of the weld are subjected to uniform force, reducing angular deformation.
The force control technology of automatic soldering machines is also reflected in the optimization of the welding sequence. By analyzing the characteristics of thin-plate structures, the system can plan the optimal welding path, avoiding stress accumulation caused by improper welding sequence. For example, when welding thin-plate frame structures, the system prioritizes welding welds at symmetrical positions to offset stresses and reduce overall deformation. Simultaneously, combined with force control feedback, the system can perform localized repair welding or pressure adjustment in high-stress areas, further eliminating potential deformation risks.
The synergy between force control technology and other functional modules of the automatic soldering machine (such as weld tracking and wire feeding control) can further enhance deformation suppression. For example, the weld tracking system can correct the welding torch position in real time, ensuring the weld is aligned with the edge of the thin plate, avoiding uneven stress caused by weld misalignment; the wire feeding control system can adjust the wire feeding speed according to pressure changes, maintaining molten pool stability and reducing deformation caused by molten pool fluctuations.
Automatic soldering machines achieve deformation suppression in thin-plate welding through force control technology, requiring a comprehensive approach encompassing mechanical structure, sensor feedback, control algorithms, process parameters, welding sequence, and functional module synergy. This process not only requires high-precision hardware support, but also relies on the deep integration of welding thermodynamics, materials mechanics and control theory to ultimately form an intelligent solution that adapts to the characteristics of thin plate welding, providing technical support for improving welding quality and production efficiency.
