Wire plasma transferred arc wire feeding control system

Abstract

The present disclosure relates to a wire plasma transferred arc wire feeding control system. A wire feeding control system includes an anti-kink mechanism and a controller configured to operate the anti-kink mechanism to maintain a wire kink measured on a trajectory between a feed of a welding wire and a plasma transferred wire arc (PTWA) torch within a predetermined range in response to the wire kink, the predetermined range being defined by a natural rotation induced into the welding wire by the PTWA torch.

Description

Technical Field

[0001] This disclosure relates to a wire plasma transfer wire arch (PTWA) feeding control system and a monitoring method for the wire feeding control system. Background Technology

[0002] Various strategies have been developed to improve vehicle fuel efficiency. For example, developing vehicle components using lightweight materials has been implemented to reduce vehicle weight. Wire plasma transferred arc (PTWA) coatings on engine components have been used to meet increasingly stringent fuel efficiency targets. For instance, PTWA coatings on aluminum alloy cylinder bores have proven to offer several advantages beyond weight reduction. For example, compared to aluminum engine cylinder blocks with thick iron cylinder liners, PTWA coatings on aluminum alloy cylinder bores reduce weight, lower costs, and reduce bore spacing. Furthermore, the PTWA process has been used to apply coatings to other vehicle components. However, the PTWA process faces several challenges. Summary of the Invention

[0003] In at least one embodiment, a wire feeding control system is disclosed. The system includes an anti-torsion mechanism. The system also includes a controller configured to operate the anti-torsion mechanism in response to wire torsion measured on a track between the wire feed section and a wire plasma transferred arc (PTWA) torch, to maintain the wire torsion within a predetermined range defined by natural rotation introduced into the wire by the PTWA torch. The controller may also be configured to derive the measured wire torsion from residual stress data of the wire. The system may further include a sensor, wherein the controller may also be configured to operate the sensor to collect the residual stress data. The sensor may be an ultrasonic sensor. The sensor may be a displacement transducer. The anti-torsion mechanism may include a set of rollers surrounding the wire. The anti-torsion mechanism may be located near the outlet of the feed section. The anti-torsion mechanism may be located near the inlet of the PTWA torch.

[0004] In an alternative embodiment, a wire feeding control system is disclosed. The system includes a controller configured to alter the twist of the welding wire based on the residual stress difference of the wire traveling between a wire feed mechanism and a wire plasma transferred arc (PTWA) torch, to prevent the degree of twist from exceeding a predetermined threshold. The system may also include an anti-twist mechanism, wherein the controller is further configured to operate the anti-twist mechanism to alter the wire twist. The anti-twist mechanism may include a set of rollers surrounding the welding wire. The anti-twist mechanism may be located near the exit of the wire feed mechanism. The predetermined threshold can be defined by the natural rotation introduced into the welding wire by the PTWA torch. The system may also include a sensor, wherein the controller is further configured to operate the sensor to collect residual stress data.

[0005] In another embodiment, a monitoring method for a wire feeding control system is disclosed. The method includes: in response to a wire twist exceeding a predetermined threshold based on a residual stress difference in the wire traveling between a wire feed mechanism and a wire plasma transferred arc (PTWA) torch, a controller alters the wire twist. The wire feeding control system may further include an anti-twist mechanism, wherein the controller is further configured to operate the anti-twist mechanism to alter the wire twist. The anti-twist mechanism may include a set of rollers surrounding the wire. The anti-twist mechanism may be located near the exit of the wire feed mechanism. The predetermined threshold may be defined by natural rotation introduced into the wire by the PTWA torch. The wire feeding control system may further include a sensor, wherein the controller is further configured to operate the sensor to collect residual stress data. Attached Figure Description

[0006] Figure 1 An exemplary schematic diagram of a prior art PTWA welding torch system is depicted, including a PTWA welding torch and a welding wire used as a consumable electrode.

[0007] Figure 2A and Figure 2B An exemplary PTWA system with a wire track and means for assisting in correcting wire twisting is shown according to one or more embodiments;

[0008] Figure 3A A perspective view of an exemplary anti-torsion mechanism is depicted, wherein the three rotating elements are in contact with the welding wire as it travels through the anti-torsion mechanism to the PTWA welding torch;

[0009] Figure 3B It shows in Figure 3A A side view of the anti-torsion mechanism depicted in the image;

[0010] Figure 3C The image shown is taken along line 3C-3C. Figure 3B A cross-sectional view of the anti-torsion mechanism;

[0011] Figure 4 A schematic diagram of a guide roller is shown, which includes an upper roller and a lower roller, wherein the upper roller is also depicted in an alternative position relative to the welding wire;

[0012] Figures 5A to 5C Illustrative example systems according to one or more embodiments are shown, depicting various positions and variable dimensions of the various devices described herein;

[0013] Figure 6 A series of steps for performing a method according to one or more embodiments are shown. Detailed Implementation

[0014] Embodiments of this disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be exaggerated or minimized to show detail of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to utilize the invention in various forms. As will be understood by those skilled in the art, various features shown and described with reference to any of the drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, various combinations and variations of features consistent with the teachings of this disclosure may be desired for particular applications or implementations.

[0015] Unless otherwise expressly stated, all numerical quantities indicating dimensions or material properties in this specification should be understood as being modified by the word “about” when describing the broadest scope of this disclosure.

[0016] The initial definition of acronyms or other abbreviations applies to all subsequent uses of the same abbreviation herein, and necessary modifications are applied to variations of the normal grammar of the abbreviations in the initial definition. Unless explicitly stated otherwise, the measurement of properties is determined by the same technique referenced earlier or later for the same properties.

[0017] In recent years, Ford and other companies have begun using PTWA and other methods to apply thin coatings to cylinder bores. A typical PTWA application involves a thin, wear-resistant coating on aluminum alloy cylinder bores. The main advantages of such an application compared to aluminum engine blocks with thick iron cylinder liners are reduced weight and / or lower cost and / or smaller bore spacing.

[0018] PTWA thermal spraying (also known as PTWA overlay) is a high-energy inert gas welding process in which a coating is deposited on a substrate. Figure 1 An example of a PTWA system 10 including a welding torch with welding wire is shown. As described above, PTWA spraying is used, for example, to coat engine cylinder bores. The method of applying the PTWA coating to the substrate is achieved by a plasma welding wire head with a protective isolating gas and wire fed with an A / C current. During PTWA spraying, powder and / or individual conductive welding wires 12 are fed into the system. A supersonic plasma jet 14 melts the welding wire 12, atomizes the welding wire 12, and propels the molten welding wire as molten particles 16 onto the substrate 17 to be coated. The plasma jet 14 is formed by a transfer arc between a tungsten cathode 18 and the welding wire 12, which serves as the anode. The propelled atomizing gas 19 transports the atomized welding wire particles 16 onto the substrate 17, wherein the particles 16 flatten as they impact the surface of the substrate 17 due to high kinetic energy. The particles 16 then rapidly solidify to form a highly abrasion-resistant coating.

[0019] As mentioned above, the PTWA process itself faces several challenges. For example, it is ideal to deliver the wire from the wire feeder to the cathode in a stable and efficient manner. However, the wire may become twisted, kinked, or otherwise exceed acceptable levels of torsion along its path to the cathode. The wire curvature can undergo various abrupt changes as it travels through the system toward the torch. These twists and changes adversely affect the reliability and efficiency of the PTWA process.

[0020] Various mechanisms have been developed to attempt to prevent undesirable wire twisting. For example, the wire feedstock can be placed on a rotary table as it is pulled out in a constant direction. Alternatively, one or more wire straighteners can be implemented in the system to attempt to keep the wire straight. However, these devices or systems cannot detect and / or manage twisting when it occurs in the wire path. Therefore, even with devices such as straighteners included in the system, residual twisting and / or reaction twisting may still exist in the wire beyond acceptable levels.

[0021] Another method is implemented only on very short tracks. The welding wire travels a shorter distance, limiting kinking and twisting within this short travel. However, this system is not suitable for normal-sized and large-sized welding wire spools and may not be cost-effective for continuous production.

[0022] Therefore, it is desirable to develop a system capable of detecting and / or managing twisting, kinking, or other undesirable behaviors of the raw wire in a PTWA system to optimize the PTWA process. It is also desirable to develop a system with an active feedback system that can sense wire twisting when it occurs and actively correct the degree of twisting to or below a threshold. Such a system will be active rather than passive.

[0023] In one or more embodiments, a wire feeding system 20 for PTWA is disclosed. Figure 2A and Figure 2B An example of a wire feeding system 20 is depicted. The wire feeding system includes a feed section 22 for welding wire raw material 24. The feed section 22 may include a welding wire coil. The feed section 22 may include a spool or another drum-shaped object for transporting, storing and / or supplying the welding wire 24 to the system 20.

[0024] The welding wire material 24 comprises a single welding wire. Welding wire 24 is a conductive welding wire suitable for PTWA applications. The material of the coating applied to the surface of the part to be coated via the PTWA process is substantially the same as the material constituting the welding wire material 24. Any conductive material capable of being melted and accelerated by a forced gas flow can be used. This material can be a metal comprising one or more metals. The material can be an ferrous material, steel. The welding wire may comprise refractory metals, low-melting-point materials, alloys, or combinations thereof. The material may include non-metallic components. The welding wire material may be corrosion-resistant. The welding wire may comprise a core and an outer layer, both having the same or different compositions. For example, the core may comprise metal oxides, metal carbides, or both metal oxides and metal carbides, etc.

[0025] The welding wire may include a protective sleeve 28 or may travel through the protective sleeve 28 during at least a portion of the welding wire track from the feed section 22 to the welding torch 26. The protective sleeve 28 may be metal, ceramic, plastic, or a combination thereof. The protective sleeve 28 has a diameter larger than that of the welding wire 24.

[0026] The welding wire 24 travels from the wire feed section 22 to the PTWA torch or spray gun 26. Any torch suitable for PTWA can be considered. The torch 26 rotates clockwise or counterclockwise. The torch 26 can also translate in other directions (such as towards and away from the wire 24 relative to its path). The torch 26 rotates for system purposes, so torch rotation is natural for the PTWA process. Therefore, the torch 26 introduces a natural rotation into the welding wire 24, and the torch 26 influences the rotation of the welding wire 24 as it travels through the system from the feed section 22 to the torch 26.

[0027] When a high-temperature (>10000°C) plasma jet is generated between the welding torch 26 (non-consumable electrode) and the welding wire 24 (consumable electrode), the welding wire 24 is fed into the rotating welding torch 26. The welding torch 26 has any size suitable for the size of the part to be coated, such that pressurized air atomizes and accelerates the droplets of molten welding wire material so that the welding wire material reaches the surface of the substrate to be coated.

[0028] System 20 also includes an anti-twist mechanism 30 capable of correcting or maintaining the degree of twist within a predetermined range. Because the welding torch 26 is rotating, the welding wire 24 twists to a certain extent. The anti-twist mechanism 30 can compensate for the twisting of the welding torch and / or the twisting present in the welding wire 24 due to the manufacturing process and unwinding from the spool or coil, so that the rotation or twisting of the welding wire 24 is maintained within a predetermined range of twist or torsion. Furthermore, when twisting or kinking occurs on the welding wire track from the feed section 22 to the welding torch 26, the anti-twist mechanism 30 can correct the twisting and kinking in the welding wire.

[0029] The term "kink" can be associated with a sudden change in the curvature of the welding wire over a relatively small distance, at least the diameter of the welding wire. The term "twist" is associated with the torsional movement of the welding wire along its long axis. Twist can be elastic or plastic. Excessive plastic deformation can cause braking of the welding wire material 24. Similarly, kink can cause permanent plastic deformation of the welding wire 24, which is undesirable.

[0030] Due to the rotation of the welding torch 26 and / or the twisting caused by the rotation of the wire feed section 22, twisting must exist at some point in the system 20. However, when the desired degree of twisting is exceeded, the amount of unwanted twisting can be considered a decrease in the efficiency of the system 20 or a need to interrupt and stop the PTWA coating process until the unwanted twisting is corrected. The desired or acceptable degree of twisting can be determined as a threshold or threshold range.

[0031] Figures 3A to 3C An example of an anti-twisting mechanism 30 is shown. The anti-twisting mechanism 30 is a mechanism that allows the raw material welding wire 24 to pass through the mechanism 30 while simultaneously untwisting the welding wire 24. The system may include one or more anti-twisting mechanisms 30. The anti-twisting mechanism 30 may be located near the guide roller 36, the feed outlet 22, the PTWA welding torch 26, or any other location along the track of the welding wire 24.

[0032] The anti-torsion mechanism 30 may include a group of objects. These objects may be rotating elements 38. The number of objects or rotating elements 38 may be 2, 3, 4, 5, 6, 7, 8, 9, or more. The rotating elements 38 can have any shape, size, and construction, as long as they can rotate about a pivot point. The rotating elements may be rollers, discs, rings, wheels, casters, or washers. The cross-sectional shape of the rotating elements may be circular, elliptical, or regular. While at least some of the rotating elements 38 may be located on a fixed axis, at least one rotating element 38 may be located on an adjustable axis to fine-tune and / or adjust the torsion of the welding wire 24. Figure 3BAs depicted, the rotating element 38' has an adjustable axis to allow it to move back and forth in a direction away from the welding wire 24 and toward the inner surface of the housing 40. Therefore, the rotating element 38' can apply a larger or smaller force to the welding wire 24 depending on its distance from the welding wire 24. In at least one embodiment, all rotating elements 38 may have an adjustable axis. Optionally or additionally, at least one or all rotating elements 38 are capable of swinging or rotating outward from the welding wire 24 (and / or away from the housing 40) to achieve welding wire mounting.

[0033] Figure 3A An example of an anti-torsion mechanism 30 including a housing 40 is shown. The housing may be arranged as a gear. The housing may have teeth, peaks, valleys, sharp or blunt edges, smooth surfaces, rough surfaces, and combinations thereof. The housing 40 may have any shape, size, or construction as long as it can secure an object that allows the welding wire 24 to pass through, untwist the welding wire, or perform both functions. The housing 40 may have inner and outer surfaces. Each surface may be the same or different depending on the material and its properties, roughness, and dimensions. The housing 40 may include one or more parts.

[0034] exist Figure 3A In the example, three rotating elements 38 are fixed within the housing 40. The rotating elements 38 may be held by an elongated object 42 (such as a pin, screw, rod, shaft, nail, belt, or clamp). Figure 3C As depicted, an elongated object 42 protrudes through the housing 40. The elongated object 42 allows force to be applied to the welding wire 24 via rotating elements 38. Each rotating element 38 has one contact point with the welding wire 24. Thus, three rotating elements 38 apply force to the welding wire 24 via three contact points. The amount of force applied by each rotating element 38 can be the same, different, maintained, or adjusted. Therefore, the anti-torsion mechanism 30 is capable of adjusting and / or maintaining a specific degree of torsion of the welding wire 24.

[0035] As described above, the amount or degree of torsion is determined by one or more controllers 32 based on data collected from one or more sensors 34. The controllers 32 may be configured to adjust the torsion of the welding wire 24 by controlling one or more components of the anti-torsion mechanism 30 to apply more or less force to the welding wire 24 by one or more rotating elements 38, by rotating the anti-torsion mechanism 30, by changing the direction and / or speed of rotation of the anti-torsion mechanism 30, or by combinations thereof.

[0036] The anti-torsion mechanism 30 can be connected via the housing 40 to a motor 44 capable of rotating the anti-torsion mechanism 30. Figure 3BAn exemplary schematic motor 44 is depicted. Motor 44 may be a geared motor. Motor 44 may have a variable rotational speed. Motor 44 may rotate the anti-torsion mechanism 30 clockwise or counterclockwise, such that the anti-torsion mechanism 30 assists in correcting the twist of the welding wire. For example, controller 32 may be configured to send a signal to motor 44 if the twist in one direction exceeds a threshold, thereby changing the rotation of the anti-torsion mechanism to apply a reverse twist to the welding wire 24.

[0037] The system may also include one or more guide rollers 36 connected to the anti-torsion mechanism 30. The number of guide rollers can be 2, 3, 4, 5, 6, 7, 8, 9, 10, or more. (As in...) Figure 4 As depicted, the guide roller 36 may include a roller mechanism comprising two rollers 46 that allow the welding wire to be fed between two rollers 46. The rollers 46 may have any size, shape, and construction, as long as the welding wire 24 can be guided and / or pulled between the two rollers 46. For example, the cross-section of the rollers may be elliptical, circular, or a regular shape. The rollers 46 may have smooth or rough surfaces. The rollers 46 may have irregularly shaped edges, teeth, burrs, etc.

[0038] At least one roller 46 is capable of changing position, for example, swinging open or rotating open to allow welding wire mounting. At least one roller 46 may be adjustable to apply variable pressure to the welding wire 24, thereby assisting in the correction of wire twisting. One or more controllers 32 may be configured to send signals to the guide roller 36 or the individually adjustable roller 46 to take corrective action.

[0039] The position of the guide rollers 36 can vary. For example, the guide rollers 36 included in system 20 can be located before and / or after each anti-twist mechanism 30, near the exit of feed section 22, near the inlet of PTWA welding torch 26, between two adjacent guide rollers 36, or anywhere along the track of welding wire 24. For example, the guide rollers 36 can be placed near the exit of welding wire feed section 22 to prevent excessive twisting due to unwinding.

[0040] The size and shape of the roller 46 can vary. For example, the system can use guide rollers 36 with rollers 46 of different sizes. Guide rollers 36 with a length longer than the remaining guide rollers 36 can be used in sections of the track that lack any device supporting the welding wire during the journey from the feed section 22 to the welding torch 26.

[0041] like Figure 2A As shown, system 20 can be a fixed-axis setup that does not require the use of a robotic arm. Conversely, in Figure 2BIn this system, system 120 may include one or more robotic arms 138. The robotic arms 138 may carry both welding wire 124 and welding torch 126. For example... Figure 2A and Figure 2B As further shown, the number and position of the anti-torsion mechanism 30 and anti-torsion mechanism 130 and / or guide roller 36 and guide roller 136 can be changed according to the system settings. Figures 5A to 5C Other embodiments (including welding torches 226, 326, 426) are further illustrated schematically, showing the variable positions of the anti-torsion mechanism 30 (230, 330, 430) and the guide rollers 36 (236, 336, 436).

[0042] The system may also include other devices, such as one or more straighteners, roller mechanisms that pull the welding wire out of the feed section 22, etc.

[0043] Return to reference Figure 2A and Figure 2B System 20 also includes one or more controllers 32. One or more controllers 32 may be configured to determine a threshold or threshold range. One or more controllers 32 may be configured to operate an anti-torsion mechanism 30 in response to a measured degree of torsion of the wire 24 on a track between the wire feed section 22 and the welding torch 26. Controllers 32 may be configured to maintain the degree of torsion within a predetermined range defined by natural rotation introduced into the wire 24 by the PTWA welding torch 26. In addition to the natural rotation of the welding torch, the system disclosed herein, including the anti-torsion mechanism 30, guide rollers 36, controllers 32, and / or sensors 34, is also capable of detecting, holding, adjusting, altering, controlling, and / or correcting other torsional events as the wire is fed into the welding torch 26.

[0044] The controller 32 can be configured to control, maintain, adjust, and alter the twisting of the welding wire 24 traveling between the welding wire feed mechanism 22 and the welding torch 26 to prevent the twisting degree from exceeding a predetermined threshold. The adjustment or alteration may include single or multiple corrections of the twisting. Based on the identified need to change the twisting degree of the welding wire 24, the adjustment may occur at regular intervals or irregularly.

[0045] One or more controllers 32 may be configured to derive measured torsion from data and / or other inputs provided by one or more sensors 34. The provided data may include residual stress data of the welding wire 24. The residual stress data may relate to data originating from within the welding wire 24. The residual stress data may relate to the shear stress value of the welding wire 24.

[0046] The controller 32 may have one or more processing components (such as one or more microprocessor units (not depicted)) that enable the controller 32 to process input data. As described above, the input data may be supplied by one or more sensors 34 included in the system 20. The input data may also be supplied by a computer system (not depicted). The input data may include: data about the welding wire material 24, such as material properties, dimensions (such as diameter, length), and residual stress data of the welding wire; data about expected, undesirable, and / or permissible torsion; the rotational speed of the welding torch; the trajectory of the welding wire; and data about the various components and functions of the anti-torsion mechanism 30 and / or guide rollers 36 (such as the distance between the various rotating elements 38 or the various rollers 46, the force applied to the welding wire 24 by the various rotating elements 38 or the various rollers 46, or combinations thereof). The input data supplied by the sensors 34 may include real-time sensing data. The sensors 34 may continuously collect signals, at predetermined intervals, or randomly, and send the signals to the controller 32.

[0047] At set intervals, one or more controllers 32 compare signals from one or more sensors 34 with a predetermined range of values ​​related to a predefined setpoint or acceptable torsion of the welding wire 24 in system 20. The set interval may include analyzing data immediately after receiving data from one or more sensors 34. If the input signal deviates from the setpoint or range, the controller 32 provides a correction output signal to one or more components of system 20. The one or more components may be one or more anti-torsion mechanisms 30. Additionally, the system may include guide rollers 36 capable of correcting the welding wire torsion. One or more controllers 32 may dynamically change the torsion of the welding wire 24 based on data provided by one or more sensors 34. The data may include residual stress exceeding a predetermined threshold, distances between the components of the anti-torsion mechanism 30 and / or guide rollers 36, forces applied to the welding wire 24 by the components of the anti-torsion mechanism 30 and / or guide rollers 36, and combinations thereof.

[0048] Sensor 34 may include one or more types of sensors. Sensor 34 may include a single-point sensor or a sensor that monitors a spectrum of values. Sensor 34 may be any sensor capable of measuring the amount of residual stress in the welding wire 24 or measuring another property that enables one or more controllers 32 to determine the amount of residual stress in the welding wire 24. For example, sensor 34 may be an ultrasonic sensor capable of sensing vibrations of the welding wire 24. The ultrasonic sensor may provide vibration data to controller 32, which may compare vibrations from different locations in the welding wire track, compare the vibrations to preset values, and / or perform calculations that result in obtaining residual stress data. Another type of sensor 34 may be a load transducer mounted as part of the anti-torsion mechanism 30 and / or guide roller 36. This type of sensor 34 may detect forces on various components of mechanism 30 or guide roller 36 such that if sensor 34 senses a force from the first rotating element 38 greater than the force from the remaining rotating elements 38, the data will indicate a system imbalance, thereby further indicating an undesirable degree of torsion. Another option for sensor 34 is a displacement transducer capable of sensing the distance or force between the various components of the anti-torsion mechanism 30 and / or guide roller 36.

[0049] Sensor 34 can be installed at various locations throughout the system 20. For example, sensor 34 may be located near the outlet of feed section 22, near (or at, on, or within) the anti-torsion mechanism 30 and / or guide roller 36, near the inlet of the PTWA welding torch, or in different sections of the wire track. The type of sensor 34 implemented determines the location. As described above, specific types of sensors 34 are suitable for applications located near various components of the anti-torsion mechanism 30 or guide roller 36, at or near at least one or all of the rotating elements 38, on the welding wire 24, or combinations thereof.

[0050] Based on input data, one or more controllers 32 determine a threshold range for residual stress. Based on real-time monitored input data, one or more controllers 32 determine, calculate, and / or compare the data from all, some, or at least a portion of the sensors 34 with the threshold range. If corrective measures are required, one or more controllers 32 send signals to one or more components of the system capable of performing corrective measures. For example, one or more controllers 32 may send signals to the motor 44 to increase or decrease the rotation of one or more anti-torsion mechanisms 30. One or more controllers 32 may send signals to the anti-torsion mechanism 30 itself to adjust the distance of one or more rotating elements 38 relative to the welding wire 24, thereby adjusting the pressure applied to the welding wire 24 by at least one rotating element 38. Other components can adjust the torsion of the welding wire in the system in other ways.

[0051] In one or more embodiments, a method is provided for monitoring welding wire fed into a PTWA system. The method includes: in response to a welding wire twist exceeding a predetermined threshold based on a residual stress difference in the welding wire 24, a controller 32 alters the twist of the welding wire 24 traveling between a wire feed mechanism 22 and a PTWA torch 26. The method may include determining an acceptable range of twist or torsion of the welding wire 24. This determination may be based on natural rotation introduced into the welding wire 24 by a rotating PTWA torch. The method may include detecting residual stress in the welding wire 24 at one or more locations between the welding wire feed section 22 and the PTWA torch 26. The method may include collecting various data regarding the welding wire 24, including residual stress in the welding wire 24. The method may include calculating torsion, twist, and residual stress based on inputs provided to the controller 32 by one or more sensors 34 and / or other resources (such as a computer system). The method may include changing, adjusting, or maintaining the twist of the welding wire 24 within a predetermined twist range. The method may include removing and / or adjusting twists and / or kinks in the welding wire 24.

[0052] The method may include inputting and / or updating system-related input data, including data relating to the material properties of the welding wire 24, the size and / or material properties of the rotating element 38, one or more anti-torsion mechanisms 30, the number and / or position of guide rollers 36 or one or more individual components of anti-torsion mechanisms 30 and / or guide rollers 36, wire feed direction, length of the welding wire track, size of the feed section 22, amount of welding wire 24 loaded on the feed section 22, type and position of sensors 34, etc. The input data may be provided to one or more controllers 32. The input data may then be processed, threshold ranges may be calculated, and welding wire torsion may be optimized based on the calculated and / or measured threshold amounts.

[0053] This may include the steps of installing one or more electronic sensors 34 at predetermined locations in the system and providing input data to one or more controllers 32. The measurement positions of one or more sensors 34 may be selected based on the data required to be provided to the controllers 32. Data from the sensors 34 may be continuously provided to the controllers 32. Input signals from the sensors 34 may be received by the controllers 32. The controllers 32 may send output signals to one or more parts of the system (such as the motor 44, rotating element 38, anti-torsion mechanism 30, and guide roller 36).

[0054] The method may include checking whether the twist of the welding wire is stable. The check may be regular, irregular, random, or repeated once or more within a set time period. The check may begin immediately after the PTWA system is started. Once the twist is detected to exceed a threshold amount, changes can be made. Changes may include increasing or decreasing the force applied to the welding wire 24 by one or more rotating elements 38. Changes may include increasing and / or decreasing the rotational speed of the motor 44. Changes may include increasing and / or decreasing the distance between one or more rotating elements 38 and / or rollers 46 and the welding wire 24 being conveyed between the rotating elements 38 and / or rollers 46.

[0055] Figure 6 A method 500 for adjusting wire twisting in the aforementioned system using a PTWA welding torch and wire feed section is illustrated. At block 502, the method can be started, wherein the system is started manually or automatically. In one example, controller 32 can start system 20. At block 504, the controller can determine a twisting threshold T of the welding wire 24 based on the provided input. C Alternatively, the threshold range, threshold amount, or threshold of the wire twist or torsion can be determined externally to the controller 32 and can be provided to the controller 32 as one of the input values. At step 506, one or more sensors 34 provide real-time signals to the controller 32. At step 508, the controller 32 determines the actual wire twist degree T based on the real-time signals from one or more sensors 34. A Then at step 510, the controller will... C With T A Compare. If T A Equal to or exceeding T C If T A Not exceeding T C If the controller does not initiate any correction behavior, and after a preset time, the controller 32 evaluates the real-time signals from one or more sensors 34 again.

[0056] The processes, methods, or algorithms disclosed herein can be transmitted to, or implemented by, a processing device, controller, or computer, wherein the processing device, controller, or computer may include any existing programmable electronic control unit or a dedicated electronic control unit. Similarly, the processes, methods, or algorithms can be stored in various forms as data or instructions executable by a controller or computer, wherein these various forms include, but are not limited to, information permanently stored in a non-writable storage medium (such as a ROM device) and information variableally stored in a writable storage medium (such as a floppy disk, magnetic tape, CD, RAM device, and other magnetic and optical media). The processes, methods, or algorithms can also be implemented in a software executable object. Optionally, the processes, methods, or algorithms can be implemented wholly or partially using suitable hardware components (such as application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), state machines, controllers, or other hardware components or devices) or a combination of hardware components, software components, and firmware components.

[0057] The terms used in this specification are descriptive and not restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of this disclosure. As previously stated, features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or shown. Although various embodiments may have been described as providing advantages or superiority over other embodiments or prior art for one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve desired overall system properties depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, lifecycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Therefore, embodiments described as less desirable in one or more aspects than other embodiments or prior art are not outside the scope of this disclosure and may be desired for specific applications.

Claims

1. A wire feeding control system, comprising: The anti-torsion mechanism is configured to correct the torsion of the welding wire within a predetermined range while allowing the welding wire to pass through. The predetermined range is defined by the natural rotation introduced into the welding wire by the rotation of the wire plasma transfer arc welding torch. sensor; as well as The controller is configured as follows: Based on the output data of the sensor, the wire twist is measured on the track between the wire feed section and the wire plasma transfer arc welding torch, and in response to the measured wire twist exceeding the predetermined range, an anti-twist mechanism is operated to keep the wire twist within the predetermined range.

2. The wire feeding control system as described in claim 1, wherein, The output data includes residual stress data of the welding wire.

3. The wire feeding control system as described in claim 1 or claim 2, wherein, The anti-torsion mechanism is located near the entrance of the wire plasma transfer arc welding torch.

4. The wire feeding control system as described in claim 1, wherein, The anti-torsion mechanism includes a set of rotating elements surrounding the welding wire.

5. The wire feeding control system as described in claim 1, wherein, The anti-torsion mechanism is located near the outlet of the feeding section or the welding wire feeding mechanism.

6. The wire feeding control system as described in claim 1, wherein, The output data includes the amount of force exerted on the welding wire by one or more individual components of the anti-torsion mechanism.

7. The wire feeding control system as described in claim 1, wherein, The sensor is an ultrasonic sensor.

8. The wire feeding control system as described in claim 1, wherein, The sensor is a displacement transducer.

9. A wire feeding control system, comprising: The anti-torsion mechanism is configured to correct the torsion of the welding wire to a predetermined threshold while allowing the welding wire to pass through. sensor; as well as The controller is configured to operate the anti-torsion mechanism to change the torsion of the welding wire based on the residual stress difference of the welding wire traveling between the welding wire feed mechanism and the wire plasma transfer arc welding torch, so as to prevent the welding wire torsion from exceeding the predetermined threshold, wherein the residual stress difference is supplied to the controller by the sensor, and wherein the wire plasma transfer arc welding torch is rotating.

10. The wire feeding control system as described in claim 9, wherein, The anti-torsion mechanism includes a set of rotating elements surrounding the welding wire.

11. The wire feeding control system as described in claim 9, wherein, The anti-torsion mechanism is located near the outlet of the feeding section or the welding wire feeding mechanism.

12. The wire feeding control system as described in claim 9, wherein, The predetermined threshold is defined by the natural rotation introduced into the welding wire by the rotation of the wire plasma transfer arc welding torch.

13. The wire feeding control system as described in claim 9, wherein, The sensor is configured to output the amount of force exerted on the welding wire by one or more independent components of the anti-torsion mechanism.

14. The wire feeding control system as described in claim 9, wherein, The sensor is an ultrasonic sensor.

15. The wire feeding control system as described in claim 9, wherein, The sensor is a displacement transducer.

16. A monitoring method for a wire feeding control system, the wire feeding control system comprising an anti-twist mechanism, a sensor, and a controller, the monitoring method comprising: In response to a wire twist exceeding a predetermined threshold due to a residual stress difference in the welding wire traveling between the wire feed mechanism and the wire plasma transfer arc welding torch, a controller operates an anti-twist mechanism to alter the wire twist, wherein the wire plasma transfer arc welding torch is rotating. The anti-torsion mechanism is configured to correct the torsion of the welding wire to no more than the predetermined threshold while allowing the welding wire to pass through, and the residual stress difference is supplied by the sensor.

17. The monitoring method as described in claim 16, wherein, The anti-torsion mechanism includes a set of rotating elements surrounding the welding wire.

18. The monitoring method as described in claim 16, wherein, The anti-torsion mechanism is located near the outlet of the feeding section or the welding wire feeding mechanism.

19. The monitoring method as described in claim 16, wherein, The predetermined threshold is defined by the natural rotation introduced into the welding wire by the rotation of the wire plasma transfer arc welding torch.

20. The monitoring method as described in claim 16, wherein, The sensor is configured to output the amount of force exerted on the welding wire by one or more independent components of the anti-torsion mechanism.

21. The monitoring method as described in claim 16, wherein, The sensor is an ultrasonic sensor.

22. The monitoring method as described in claim 16, wherein, The sensor is a displacement transducer.

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