Arc Welding Power Supply Cyclic Wire Feeding
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Solution Overview
Problem
Existing arc welding methods face challenges in improving welding quality, particularly in reducing blow holes, due to limitations in controlling the feeding speed and arc length of consumable electrodes.
Innovation Solution
An arc welding power supply with an output control unit, feed control unit, and amplitude control unit that adjusts power and cyclically changes the feeding speed of the welding wire, including forward and rearward speeds, to vary the average arc length and enhance molten pool agitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the feeding speed of the welding wire is cyclically changed to vary arc length, then molten pool agitation increases and welding quality improves, but control system complexity increases
Solution Approach 1:
The patent implements periodic action by cyclically changing the feeding speed of the welding wire through predetermined forward and rearward speeds. This periodic variation in feeding speed creates corresponding variations in arc length, which generates effective agitation in the molten pool to reduce blow holes and improve welding quality without requiring complex real-time control systems.
Solution Approach 2:
The patent applies dynamics by transitioning from static feeding speed to dynamic cyclically varying feeding speed. The amplitude control unit dynamically adjusts the amplitude of feeding speed variation, allowing the system to adapt the degree of molten pool agitation based on welding conditions while maintaining a relatively simple control architecture through predetermined speed patterns.
2Manufacturing precision
If the feeding speed amplitude is increased to enhance molten pool agitation, then blow hole reduction improves, but welding process stability deteriorates
Solution Approach 1:
The patent implements parameter changes by systematically varying the amplitude parameter of feeding speed in a controlled manner. The amplitude control unit adjusts the amplitude between predetermined minimum and maximum values, creating optimal molten pool agitation to reduce blow holes while maintaining welding process stability through defined parameter ranges and cyclic patterns.
3Manufacturing precision
If cyclic feeding speed variation is implemented to improve welding quality, then molten pool agitation increases, but energy consumption increases
Solution Approach 1:
The patent applies partial action by implementing feeding speed variation only during specific phases of the welding cycle rather than continuous variation. The system uses predetermined forward and rearward feeding speeds that provide sufficient molten pool agitation to reduce blow holes while minimizing unnecessary energy consumption through targeted, phase-specific speed adjustments.
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 solution effectively reduces blow holes and improves welding quality by increasing the agitation of the molten weld pool, resulting in better bead quality and reduced defects.
Implementation Method 1
an arc is generated from the distal electrode end of the welding wire to weld a welded article (base material)
Implementation Method 2
cyclically vary an average arc length... increasing the agitation of the molten pool
Data Source
AI summary
An arc welding power supply supplies power to a welding wire functioning as a discharge electrode to generate an arc from an electrode distal end of the welding wire and perform arc welding on a welded article. The arc welding power supply includes an output control unit that adjusts the power supplied to the welding wire to a power value suitable for arc welding. A feed control unit cyclically changes a feeding speed of the welding wire. The feeding speed includes a forward feeding speed and a rearward feeding speed. An amplitude control unit cyclically changes an amplitude of the feeding speed of the welding wire to cyclically vary an average arc length.