AC Submerged Arc Welding Waveform Control for Stable Effective Current
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In AC submerged arc welding, varying the lengths or peak currents of the electrode positive (EP) and electrode negative (EN) periods leads to significant variations in the effective current, often exceeding 100 A, making it challenging to maintain a stable penetration depth and wire deposition rate.
Innovation Solution
A submerged arc welding machine and method that quickly calculates other parameters of the AC current waveform by using pre-stored tables associating manipulation parameters with function values, ensuring the effective current matches a predetermined target current, even when various manipulation parameters are changed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the length or peak current of the EP period and EN period is varied to control penetration shape and wire deposition rate, then the penetration shape and wire deposition rate can be controlled, but the effective current varies significantly (exceeding 100 A variation)
Solution Approach 1:
The patent pre-calculates and stores correspondence relationships between manipulation parameters (EP period length, EN period length, peak currents) and resulting effective currents in tables before welding operations. When welding parameters need to be adjusted, the system quickly retrieves pre-calculated data from these tables to determine the appropriate effective current, avoiding significant variations and eliminating the need for complex real-time calculations during the welding process itself.
2Ease of operation
If simple manipulation methods are used to change parameters in association with each other, then the operation is simple, but the effective current variation cannot be completely eliminated
Solution Approach 1:
The system performs comprehensive pre-calculations of effective current values for various combinations of manipulation parameters and stores them in lookup tables. During actual welding operations, operators can simply select from pre-defined parameter combinations or make small adjustments, and the system quickly retrieves the corresponding effective current values from the stored tables, maintaining both operational simplicity and effective current stability without requiring complex real-time computations.
Data Source
AI summary
Provided is a submerged arc welding method including: preparing a plurality of tables in which two or three manipulation parameters and function values are associated with each other in order to associate a plurality of the manipulation parameters for manipulating an AC waveform of a current output from a welding power supply and parameters for determining the AC waveform in combination with the plurality of manipulation parameters with matching between an effective value of the output current and a predetermined current set as a constraint condition; receiving the plurality of manipulation parameters; and calculating the parameters with reference to the plurality of tables by using the plurality of received manipulation parameters.