Arc-Tracking Welding Using High-Frequency Resistance Detection
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Solution Overview
Problem
Conventional arc-tracking welding techniques face challenges in achieving high accuracy, particularly when the weaving amplitude is small or the thickness of target plates is small, and simple resistance value detection is influenced by control loop effects, resulting in a low signal-to-noise ratio.
Innovation Solution
The method involves incorporating a high-frequency component into the welding current and voltage supplied to the consumable electrode, detecting resistance values based on these signals, and using the detected resistance value to determine deviations from the welding line, with the high-frequency component set to a frequency higher than the weaving frequency, such as 100 Hz or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple resistance value detection is used for arc-tracking, then the device complexity is reduced, but the measurement precision deteriorates due to low signal-to-noise ratio and control loop influence
Solution Approach 1:
The invention applies periodic action by superimposing a high-frequency component (100 Hz or higher) on the welding current and voltage. This periodic high-frequency signal enables precise measurement of resistance value variations by creating detectable oscillations that are not present in conventional DC or low-frequency welding processes. The high-frequency periodic action allows the detection system to distinguish actual resistance changes from noise and control loop variations, thereby improving measurement precision without increasing device complexity.
2Manufacturing precision
If the weaving amplitude is reduced for thin plates, then the manufacturing precision is improved, but the measurement precision deteriorates due to insufficient resistance value variation
Solution Approach 1:
By superimposing a high-frequency component on the welding current and voltage, the invention amplifies the resistance value variations that occur during weaving operations on thin plates. Even when the weaving amplitude is small, the high-frequency oscillations create sufficient signal variation for accurate detection. This allows precise measurement of torch position deviations while maintaining small weaving amplitudes required for thin plate welding, thereby resolving the contradiction between manufacturing precision and measurement precision.
Solution Approach 2:
The invention changes the frequency parameter of the welding current and voltage by superimposing a high-frequency component (100 Hz or higher). This parameter change transforms the electrical characteristics of the welding process, enabling the detection system to measure resistance value variations with high precision even when mechanical parameters (weaving amplitude) are reduced for thin plate applications.
3Measurement precision
If the high-frequency component frequency is increased to improve detection accuracy, then the measurement precision is improved, but the energy consumption increases
Solution Approach 1:
The invention applies partial action by superimposing a relatively small high-frequency component on the main welding current and voltage. The high-frequency component is not the primary energy carrier but serves as a measurement signal. By using a moderate frequency (100 Hz or higher) rather than extremely high frequencies, the invention achieves sufficient measurement precision while minimizing the additional energy consumption associated with the high-frequency component.
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
This approach enables accurate arc-tracking by enhancing the detection of resistance value variations, improving the signal-to-noise ratio and allowing for precise deviation detection, even in cases with small weaving amplitudes or thin plates.
Implementation Method 1
causing a welding current and a welding voltage supplied to a consumable electrode to include a high-frequency component having a frequency higher than a frequency of the weaving
Implementation Method 2
detecting values of the welding current and the welding voltage during welding; determining a resistance value on the basis of the detected values of the welding current and the welding voltage
Implementation Method 3
In arc welding, 'arc-tracking' is used commonly in which a deviation of a wire tip position from a joining position of welding is detected
Data Source
AI summary
An arc-tracking welding method according to the present invention is an arc-tracking welding method in a consumable-electrode-type welding apparatus provided with a weaving function for swinging a torch in the welding direction, wherein a welding current and a welding voltage to be supplied to a consumable electrode include high-frequency components. A change in resistance value resulting from a fluctuation in electrode height is detected from the welding current and the welding voltage during welding. Then, a shift of a weld line is detected from information about the detected resistance value and both end positions of a weaving amplitude.