Maintaining arc stability is one of the key goals in robotic welding. Arc instability not only causes defects such as porosity and splatter but also affects weld strength and appearance. Besides welding current and process settings, the motion control system plays a vital role, especially the servo motor’s control algorithm. This article discusses how advanced control algorithms in GXServo contribute to optimizing arc stability.
First, arc stability requires extremely smooth torch movement. Any sudden acceleration, deceleration, or jitter can cause arc length fluctuations. GXServo adopts a dual-loop control strategy—combining velocity and position loops—for smooth and precise motion control. This dual-loop design allows the servo to quickly correct minor deviations while maintaining overall smoothness.
Second, the feedforward control algorithm embedded in GXServo helps anticipate load changes and compensate in advance. For example, when approaching a corner or change in direction, the servo can predict the required torque and speed based on trajectory analysis, achieving motion without delay and avoiding arc disruption due to sudden load changes.
Additionally, GXServo’s adaptive gain adjustment technology can automatically adjust PID parameters based on load, speed, and feedback signal status. This ensures optimal system stability and responsiveness in different welding tasks, reducing the need for frequent manual tuning and avoiding arc instability due to mismatched gain settings.
In high-speed welding, maintaining precise acceleration control is critical. GXServo supports S-curve acceleration/deceleration, which avoids sudden torque spikes and improves motion smoothness. This is particularly beneficial in lap welding or fillet welding where speed and quality must both be ensured.
Furthermore, vibration suppression is an important control strategy. GXServo integrates notch filters and vibration damping algorithms that can automatically identify mechanical resonance frequencies and reduce their effects, preventing micro-oscillations at the torch tip that could lead to arc instability.
Finally, data feedback from GXServo provides real-time torque, speed, and position status, which can be used to build welding quality monitoring systems. By correlating motion parameters with arc signal feedback, the system can diagnose and adjust welding processes in real time, achieving true intelligent arc control.
In conclusion, advanced control algorithms in servo systems like GXServo not only improve the motion performance of welding robots but also play a key role in stabilizing the arc and ensuring welding quality. In pursuit of high-end intelligent welding, algorithmic servo control has become an indispensable part of the solution.
