Arc Start Control for Faster Robotic Welding Without Quality Loss
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Solution Overview
Problem
In arc welding processes, especially when using a welding robot, the time from when the welding torch reaches the welding start position to when the arc forms is unnecessarily prolonged, leading to decreased productivity.
Innovation Solution
An arc start adjustment device that automatically adjusts the arc start procedure by obtaining welding data and using a procedure adjustment unit to shorten the cycle time without compromising welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If arc start processing is executed in advance by slowing down the wire feeding, then the cycle time is shortened and productivity is improved, but the welding quality may be deteriorated
Solution Approach 1:
The system performs preliminary actions (slowing down wire feeding, pre-heating) before the welding torch reaches the start position to enable arc formation in advance. This reduces the idle time between torch arrival and arc start, thereby shortening the cycle time and improving productivity.
Solution Approach 2:
The wire feeding speed is dynamically adjusted based on the distance between the welding torch and the start position. As the torch approaches, the wire feeding speed is automatically reduced to optimize arc formation timing. This dynamic control enables precise timing of arc start, maintaining welding quality while reducing cycle time.
Solution Approach 3:
The system uses feedback from the welding robot's position detection to control the wire feeding speed and arc start timing. By continuously monitoring the torch position and adjusting the wire feeding accordingly, the system achieves optimal arc formation timing, thereby shortening cycle time without compromising welding quality.
2Productivity
If the wire slow down speed is set to high to shorten arc start processing time, then the cycle time is reduced, but the welding quality may be deteriorated
Solution Approach 1:
The wire slow down speed is not fixed but dynamically adjusted based on real-time conditions such as the distance to the start position and welding parameters. This dynamic adjustment allows the system to achieve fast arc formation when conditions permit, while maintaining welding quality by reducing the slow down speed when necessary.
Solution Approach 2:
The system changes the wire feeding speed parameter adaptively during the approach to the welding position. By optimizing the slow down speed parameter based on measured conditions, the system achieves the fastest possible arc formation that still maintains acceptable welding quality, thereby resolving the contradiction between productivity and quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device effectively shortens the cycle time of the welding process, enhancing productivity while maintaining or improving welding quality.
Implementation Method 1
an electric arc is caused between a welding wire fed to a region to be welded of a base metal and the base metal
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.