Abstract: A mathematical model for consumable double-electrode gas metal arc welding (DE-GMAW) is established by using the equivalent path method and then the simulations about welding process are carried out which. During the simulation, aiming to the requirement of stably welding process, a control plan is proposed to control the stability of decoupling arc shape with the bypass wire extension as controlled object. Based on Matlab/Simulink and xPC-real-time target environment, the simulation, analysis, prediction and experiment about this control scheme are accomplished. The results show that mathematical model can reflect the process of consumable DE-GMAW well; Simulation and analysis can confirm the control scheme; the experiment can prove simulation results and obtain good weld formation on the basis of stable welding process.

Key words: Control, Coupling arc, Gas metal arc welding, Simulation