Arc Welding Feed Cycle Control for Stable Metal Transfer
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Solution Overview
Problem
In arc welding with alternating feeding rates, changes in voltage setting values lead to unstable welding states due to changes in droplet transfer states, especially when the voltage setting value differs based on welding conditions like joint shape, speed, or posture.
Innovation Solution
An arc welding control method that adjusts the feeding rate cycle based on the voltage setting value, using feedback control to maintain a stable welding state by optimizing the cycle of the feeding rate in response to changes in voltage settings, ensuring synchronization with short-circuiting and arc periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the voltage setting value is changed according to welding conditions, then the welding quality is improved, but the droplet transfer state changes causing welding state instability
Solution Approach 1:
The patent applies dynamics by making the feeding rate cycle period variable rather than fixed. The control device dynamically adjusts the feeding rate cycle period based on the voltage setting value, allowing the system to adapt to changing welding conditions while maintaining stable droplet transfer. This resolves the contradiction by enabling both voltage adjustment for quality and dynamic compensation for stability.
Solution Approach 2:
The patent changes the parameter of feeding rate cycle period in response to voltage setting value changes. By establishing a correspondence between voltage setting values and optimal feeding rate cycle periods, the system maintains stable droplet transfer states across different welding conditions. This parameter adjustment prevents the instability that would otherwise result from voltage changes alone.
2Stability of the object's composition
If the feeding rate cycle is adjusted to match voltage setting changes, then the welding state stability is maintained, but the control system complexity increases
Solution Approach 1:
The patent implements feedback control where the control device monitors the voltage setting value and automatically adjusts the feeding rate cycle period accordingly. This closed-loop approach maintains welding state stability by continuously adapting to voltage changes, while the automated nature of the feedback reduces the need for complex manual intervention or overly complicated control architecture.
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
The method maintains a stable welding state even with varying voltage setting values by optimizing the feeding rate cycle, reducing instability and improving welding quality by synchronizing the feeding rate with voltage changes.
Implementation Method 1
generating an arc between the welding wire and base material
Data Source
Figure 1
Figure 2(A)~2(C)
Figure 3
AI summary
Provided is an arc welding control method that performs welding by alternately switching feed rate (Fw) for welding wire (1) between a forward feed period and a reverse feed period, controlling welding voltage (Vw) on the basis of a voltage setting value, and repeating a short period and an arc period, wherein a smoothed value for welding voltage (Vw) is detected and a cycle (Tf) of the feed rate (Fw) is feedback controlled such that this smoothed value for welding voltage and the voltage setting value are the same. Thereby, the cycle (Tf) of the feed rate (Fw) is made appropriate in correspondence with changes in the metal transfer mode accompanying changes in voltage setting value; therefore, it is possible to control occurrences of synchronization offsets in the cycle of forward feed and reverse feed for the feed rate (Fw) and the cycle of the short period and the arc period, and maintain stable welding conditions.