Arc Welding Control with Cooling Pauses to Prevent Melt-Off
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Solution Overview
Problem
In arc welding, the formation of a large molten pool next to the initial molten pool can lead to the melting-off of molten metal, especially when welding torch direction or member distance affects molten metal stability.
Innovation Solution
A welding apparatus that alternates between periods of arc welding and cooling to form a scaly weld bead, with a predefined ratio of welding and cooling times to ensure molten pool solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous arc welding is performed to form a linear weld bead, then welding efficiency is improved, but molten metal may melt off due to large molten pool formation
Solution Approach 1:
The patent applies periodic action by alternating between arc welding periods and cooling periods. During the cooling period, the arc welding is stopped to allow the molten pool to cool and solidify, preventing molten metal from melting off. This periodic on-off cycling of the welding process resolves the contradiction between maintaining welding efficiency and preventing molten metal instability.
2Reliability
If cooling period is extended to solidify molten pool, then molten metal melting-off is suppressed, but weld bead formation time increases
Solution Approach 1:
The patent applies parameter changes by optimizing the ratio of the cooling period (second time period) to the welding period (first time period) within the range of 0.2 to 2.0. This parameter optimization ensures that the molten pool has sufficient time to cool and solidify properly, preventing molten metal from melting off, while avoiding excessive cooling time that would unnecessarily extend the total weld bead formation time.
3Reliability
If arc welding is stopped frequently to cool welding point, then molten metal melting-off is prevented, but welding speed decreases
Solution Approach 1:
The patent applies periodic action by implementing a controlled cycle of welding and cooling periods. The cooling period is optimized to be between 0.2 to 2.0 times the welding period, which allows the molten pool to cool sufficiently to prevent melting-off while minimizing the interruption time. This balanced periodic approach maintains both weld bead quality and acceptable welding speed.
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
Suppresses molten metal melting-off and reduces the time required to form a weld bead of the desired length by cooling and solidifying the molten pool during pauses in welding.
Implementation Method 1
an arc welding unit configured to perform arc welding
Implementation Method 2
stop the arc welding for a second time period, which is predefined time period, so as to cool a welding point formed by the arc welding
Data Source
AI summary
Disclosed is a welding apparatus configured to suppress the occurrence of melting-off of molten metal. A welding apparatus of the present disclosure includes: an arc welding unit configured to perform arc welding, a moving mechanism for moving the arc welding unit, and a control unit configured to control execution of the arc welding and movement by the moving mechanism, in which the control unit is configured to: execute the arc welding for a first time period, which is predefined time period; stop the arc welding for a second time period, which is a predefined time period, so as to cool a welding point formed by the arc welding; and move the arc welding unit and resume execution of the arc welding after lapse of the second time period.