Arc-Tracking Welding Waveform Fitting for Precise Deviation Detection

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Solution Overview

Problem

Existing arc-tracking welding methods are insufficient in accurately detecting deviations from the welding line due to reliance on limited data points and high sensitivity to variations in welding conditions, leading to suboptimal control accuracy and a restricted range of selectable welding conditions.

Innovation Solution

A method that fits a periodic waveform function to the welding current or voltage waveform during the weaving operation to detect deviations, using sine and cosine waves with periods matching the weaving cycle, allowing for continuous data accumulation and sequential fitting to improve detection accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional arc-tracking methods use limited data points (e.g., four points per weaving period) for deviation detection, then the detection process is simple and fast, but the measurement precision and reliability of deviation detection deteriorate

Engineering Contradiction:

Improvedeviation detection precisionVSAvoiddetection method complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies periodic action by utilizing the periodic nature of weaving operations to perform waveform fitting. The welding current or voltage waveform is fitted with a periodic function having the same period as the weaving operation, allowing continuous utilization of periodic data patterns to improve detection precision without proportionally increasing complexity

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent implements continuity of useful action by performing waveform fitting using all available welding current/voltage data throughout the weaving period rather than discrete sampling. This continuous utilization of data improves measurement precision by incorporating the entire waveform information while maintaining computational efficiency through systematic fitting methods

Inventive Principle:

Principle #20Continuity of useful action

2Manufacturing precision

If conventional methods rely on simple arithmetic operations on limited current values, then the computational process is simple, but the manufacturing precision and control accuracy of welding deteriorate

Engineering Contradiction:

Improvewelding line tracking accuracyVSAvoidcontrol method complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by transforming the control approach from simple arithmetic operations on discrete current values to waveform fitting using periodic functions. This changes the mathematical parameters from basic differences to fitted waveform characteristics, significantly improving welding line tracking accuracy while the systematic fitting methodology keeps computational complexity manageable

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the mechanical/arithmetic computation system with a waveform analysis system. Instead of mechanically computing differences between discrete current values, the system uses waveform fitting techniques that replace simple arithmetic with continuous function analysis, improving manufacturing precision through more sophisticated mathematical modeling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If conventional arc-tracking is highly sensitive to variations in welding conditions, then it can adapt to different conditions, but the stability of tracking performance deteriorates

Engineering Contradiction:

Improveadaptability to welding conditionsVSAvoidtracking performance stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent applies universality by developing a waveform fitting method that functions across multiple welding conditions and parameters. The periodic waveform fitting approach serves as a universal solution that adapts to different weaving widths, frequencies, and welding parameters while maintaining stable tracking performance through the robustness of periodic function fitting

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements beforehand cushioning by using waveform fitting that inherently smooths out variations and noise in the welding current/voltage signals. The periodic function fitting acts as a pre-processing cushion that stabilizes the tracking performance before deviation calculation, reducing the impact of welding condition variations on tracking stability

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11235414B2Method of detecting amount of discrepancy in arc tracking welding

Publication Date: 2022.02.01 KOBE STEEL LTD

AI summary

In a method for detecting a deviation in arc-tracking welding, a deviation between a welding line and an actual welding position is detected in arc-tracking welding for performing welding tracking the welding line while performing a weaving operation of swinging a welding torch with respect to a welding direction. The method includes fitting a waveform expressed by a function repeated periodically in a period equal to a weaving period to a waveform of a welding current or a welding voltage and detecting a deviation in arc-tracking welding based on a fitted waveform.