Arc Start Timing Control for Faster Welding Cycle Time
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Solution Overview
Problem
The existing arc welding processes face inefficiencies in productivity due to unnecessary robot downtime during the arc start procedure, leading to prolonged cycle times and potential deterioration in welding quality when attempting to shorten this time manually.
Innovation Solution
An arc start adjustment device that utilizes neural networks to automatically adjust the arc start procedure based on real-time welding data, determining optimal parameters such as wire feeding speed and welding current timing to minimize cycle time without compromising welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If arc start processing is executed in advance to shorten cycle time, then productivity is improved, but welding quality may be deteriorated
Solution Approach 1:
The wire feeding speed is reduced in advance before the welding torch reaches the welding start position, and the arc start processing is executed ahead of time. This preliminary action allows the arc to form earlier, shortening the cycle time while maintaining welding quality through controlled parameter adjustment.
Solution Approach 2:
The invention dynamically adjusts wire feeding speed parameters and arc start timing based on the distance between the welding torch and the welding start position. By changing these parameters adaptively, the system achieves both shortened cycle time and maintained welding quality.
2Productivity
If wire slow down speed is set to high to shorten arc start processing time, then productivity is improved, but welding quality may be deteriorated
Solution Approach 1:
The wire feeding speed is dynamically adjusted based on real-time conditions. The system reduces wire feeding speed in advance at a controlled rate, then increases it appropriately during arc start processing. This dynamic adjustment optimizes both processing speed and welding quality.
Solution Approach 2:
The wire feeding speed is reduced in advance before the welding torch reaches the welding start position. This preliminary speed reduction prepares the system for faster arc start processing while preventing quality deterioration through controlled parameter management.
3Manufacturing precision
If the robot waits for arc formation after reaching welding start position, then welding quality is ensured, but productivity decreases
Solution Approach 1:
The arc start processing is executed in advance before the welding torch reaches the welding start position. By initiating arc formation earlier through preliminary wire feeding speed reduction and timing adjustment, the system eliminates the waiting period while ensuring quality through controlled parameter management.
Solution Approach 2:
The invention eliminates the idle waiting time between the welding torch reaching the start position and arc formation. By continuously optimizing wire feeding speed and arc start timing, the system maintains productive action throughout the entire process without interruption.
Data Source
AI summary
An arc start adjustment device adjusting an arc start procedure in a welding process comprises an obtainment unit that obtains welding data indicating a welding state during or after a welding process, and a procedure adjustment unit that adjusts the arc start procedure such that the cycle time of the welding process is shortened based on welding data obtained by the obtainment unit.