Arc Welding Control System for Groove Angle Adaptation
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Solution Overview
Problem
Conventional arc welding control systems face challenges in simultaneously optimizing weaving width and torch height control operations, leading to potential weld defects and reduced performance due to interdependent control operations that often result in either incomplete control cycles or excessive gain reduction.
Innovation Solution
An arc welding control system that uses an arc sensor to detect welding current or voltage, calculating manipulated variables for both weaving width and torch height based on deviations from target values, with influence ratios adjusted according to the groove angle to prioritize torch height control, allowing for simultaneous and sophisticated control of both parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If weaving width control and torch height control are performed independently, then each control operation can be optimized individually, but the controls influence each other causing weaving width to deviate from target value and control stability to deteriorate
Solution Approach 1:
The patent merges weaving width control and torch height control into a unified control system that calculates manipulated variables for both parameters simultaneously. The control unit integrates both control operations and adjusts weaving width and torch height based on combined feedback, eliminating the interference that occurs when controls are performed independently.
Solution Approach 2:
The patent implements a feedback mechanism where the control unit continuously monitors both weaving width and torch height, compares actual values with target values, and adjusts manipulated variables based on the deviations. This closed-loop feedback ensures that changes in one parameter do not cause destabilizing effects on the other parameter.
2Reliability
If gain is decreased to prevent weld defects during independent control operations, then weld quality is maintained, but control performance and response speed are reduced
Solution Approach 1:
By combining weaving width control and torch height control into a unified system, the patent can maintain higher gain values without causing weld defects. The integrated control properly accounts for the interaction between parameters, allowing faster response speeds while ensuring weld quality through coordinated adjustment of both parameters.
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
Enables quick and optimal control of weaving width and torch height without reducing gain, preventing weld defects and ensuring stable target values are achieved, even at varying groove angles.
Implementation Method 1
arc welding with respect to a workpiece that is a welding target while causing a welding torch to automatically track a weld line of the workpiece
Implementation Method 2
the position of the welding torch is understood by detecting an arc welding current or arc voltage generated between the workpiece and an electrode projecting from a tip end of the welding torch
Data Source
AI summary
The present invention provides an arc welding control system and method capable of simultaneously, sophisticatedly performing a weaving width control operation and a torch height control operation. Influence ratios (δw and δz) of influences of a torch height deviation (ΔPh) and a groove wall distance deviation (ΔPd) with respect to a manipulated variable (Δw) of a weaving width and a manipulated variable (Δz) of a torch height are set in accordance with a groove angle (θ) of a workpiece (5). A calculation unit (21) calculates the manipulated variables (Δz and Δw) of actuators (13 and 14) regarding the torch height and the weaving width such that the influence ratios (δw and δz) become large as the groove angle (θ) becomes large.