Arc Welding Burnback Control via Wire Feed Speed
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Solution Overview
Problem
Conventional arc welding systems require manual adjustment of burnback time and wire feed speed, which can lead to inefficiencies and inconsistencies in preventing the wire electrode from sticking to the weld, as the burnback time is not automatically adjusted based on the selected wire feed speed.
Innovation Solution
An arc welding system that automatically adjusts burnback time in response to the selected wire feed speed using an addressable electronic look-up-table, allowing for a predetermined relationship between burnback time and wire feed speed, with optional manual adjustments through a trim knob.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of burnback time is used, then the system is simple to operate, but the welding consistency and wire sticking prevention are poor
Solution Approach 1:
The system automatically adjusts burnback time based on wire feed speed selections without requiring manual intervention. The microprocessor monitors wire feed speed and autonomously selects appropriate burnback time values from stored data, allowing the system to self-regulate the burning back process based on operating conditions.
Solution Approach 2:
The system continuously monitors wire feed speed and uses this information to dynamically adjust burnback time. The microprocessor receives feedback about the selected wire feed speed and automatically modifies the burnback time parameter to maintain optimal welding conditions and prevent wire sticking.
2Productivity
If separate selection of burnback time and wire feed speed is required, then the system offers flexibility, but the operation time and complexity increase
Solution Approach 1:
The system combines the selection of wire feed speed and burnback time into a single automated process. When the operator selects wire feed speed, the microprocessor automatically determines and applies the appropriate burnback time from stored data, merging two separate parameter selections into one unified operation.
Solution Approach 2:
The system pre-stores optimal burnback time values corresponding to different wire feed speeds in the microprocessor memory. This preliminary preparation allows the system to instantly retrieve and apply the correct burnback time without requiring real-time calculation or manual adjustment, saving operator time and improving efficiency.
3Reliability
If burnback time is not adjusted based on wire feed speed, then the system is simple to control, but wire sticking occurs frequently
Solution Approach 1:
The microprocessor-based control system autonomously monitors wire feed speed and automatically adjusts burnback time without requiring complex manual control mechanisms. The system self-regulates by selecting appropriate burnback time values from stored data based on the selected wire feed speed, improving wire sticking prevention while maintaining relatively simple operation.
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
Ensures consistent and efficient prevention of wire electrode sticking by automatically optimizing burnback time based on wire feed speed, enhancing the welding process by eliminating the need for separate selection of burnback time and wire feed speed.
Implementation Method 1
The welding power source provides the electric current which is provided to the wire electrode
Implementation Method 2
burnback time is a relatively short period of time occurring at the end of a weld when the wire feed stops but electric current is still applied to the wire electrode
Data Source
AI summary
An arc welding system and method where burnback time (BBT) is correlated to wire feed speed (WFS). Means for feeding a wire electrode toward a workpiece and means for selecting a wire feed speed (WFS) are provided. Also, means for automatically adjusting a burnback time (BBT) of the wire electrode in response to the selected wire feed speed (WFS) is provided.