Arc Welding Current Suppression for Stable Droplet Transfer
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Solution Overview
Problem
In consumable electrode arc welding, the droplet formed at the end of the welding wire tends to rise away from the base material due to inertial and arc forces when fed in reverse, hindering proper transfer during the arc period.
Innovation Solution
An arc welding apparatus and method that includes a power supply and wire feeder controlled to perform unit welding steps with a short circuit stage and an arc stage, featuring a current suppression period during the transition from short circuit to arc, where the welding current is reduced to prevent droplet rising, and specific acceleration phases to manage wire feeding rates effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding wire is fed in reverse direction during the arc period, then the welding process can be controlled alternately with short-circuiting and arc periods, but the droplet rises away from the base material due to inertial and arc forces, hindering proper transfer
Solution Approach 1:
The controller suppresses the welding current in advance during the transition period from short-circuiting to arc period, before the wire feeding direction changes. This preliminary current suppression prevents the generation of strong arc forces that would otherwise cause droplet rising, ensuring proper droplet transfer to the base material when forward feeding begins
Solution Approach 2:
The welding current is dynamically adjusted based on the wire feeding rate changes. The controller detects when the wire feeding rate is changing (transition period) and automatically suppresses the current during this dynamic phase, then restores normal current levels when the wire feeding rate stabilizes, adapting the electrical parameters to the mechanical feeding conditions
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 ensures proper droplet transfer to the base material by weakening the arc force during the transition period, preventing undesired droplet rising and maintaining arc quality throughout the welding process.
Implementation Method 1
a power supply that supplies welding power to a path including an welding wire and a base material
Implementation Method 2
an arc is generated between the welding wire and the base material
Data Source
AI summary
An arc welder includes a welding power supply, a forward/reverse welding wire feeder, and a controller for the power supply and the wire feeder. Welding is implemented by repeating unit welding steps each including a short circuit stage with the welding wire and a base material being short-circuited and an arc stage with an arc being generated between the wire and the material. A transition period continues from a starting point of the arc stage till the wire feeding rate reaches a forward maximum. An average welding current is defined as an average of the welding current during the short circuit and arc stages. Within the transition period, the controller sets a current suppression period during which welding current is smaller than the average welding current. Transition period length T0 and current suppression period length T1 are set to satisfy the inequality 0<T1/T0≤0.8.