Arc Welding Wire Feed Cycling for Stable Short-Circuit Transfer
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Solution Overview
Problem
Conventional arc welding methods with consumable electrodes face issues of increased spatters and unstable arc stability due to high wire feeding speeds, leading to frequent short circuits and prolonged short-circuit periods.
Innovation Solution
A method of controlling arc welding that alternates between forward and backward wire feeding with cyclically changed speeds, incorporating feeding stop steps to reduce impact and stabilize short-circuit cycles, ensuring reliable droplet formation and transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire feeding speed is increased to improve productivity, then welding efficiency is improved, but spatters increase and arc stability deteriorates
Solution Approach 1:
The patent applies periodic action by cyclically changing the wire feeding speed between forward feeding (higher speed) and backward feeding (lower speed or reverse direction). This periodic variation in feeding speed prevents continuous high-speed collision between the wire and base material, thereby reducing spatter generation while maintaining overall welding productivity through the alternating feeding pattern.
Solution Approach 2:
The patent implements dynamics by making the wire feeding speed variable rather than constant. The feeding speed is dynamically adjusted based on the feeding direction (forward or backward) and the welding state, allowing the system to adapt to different operational requirements and reduce harmful effects of high-speed feeding.
2Productivity
If the wire feeding speed is increased to improve productivity, then welding efficiency is improved, but arc stability deteriorates due to prolonged short-circuit period
Solution Approach 1:
The periodic alternation between forward and backward feeding creates a rhythmic pattern that prevents prolonged short-circuit conditions. By regularly switching feeding directions and speeds, the system avoids continuous high-speed wire collision that would extend the short-circuit period, thereby maintaining arc stability while preserving welding productivity.
Solution Approach 2:
The patent changes the wire feeding speed parameter dynamically based on feeding direction and welding state. During backward feeding, the speed is reduced or reversed, which shortens the short-circuit period and prevents arc instability, while forward feeding operates at higher speeds for productivity. This parameter adaptation resolves the contradiction between speed and stability.
3Productivity
If the wire feeding speed is constantly controlled at high speed to improve productivity, then welding efficiency is improved, but spatters increase due to vigorous wire collision with base material
Solution Approach 1:
The patent employs periodic action by alternating between forward feeding at high speed (for productivity) and backward feeding at low or reverse speed (to reduce collision). This periodic switching prevents continuous vigorous wire collision with the base material, thereby reducing spatter generation while maintaining overall welding efficiency through the alternating pattern.
Solution Approach 2:
The system dynamically adjusts the wire feeding speed based on the feeding direction and welding state. During forward feeding, higher speeds are used for productivity, while during backward feeding, speeds are reduced or reversed to minimize wire collision and spatter. This dynamic parameter adjustment resolves the contradiction between productivity and spatter reduction.
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 reduces spatters and enhances arc stability by minimizing the impact of wire collisions and stabilizing the short-circuit cycle, resulting in improved welding quality and reduced variations in the short-circuit period.
Implementation Method 1
when the welding wire is fed forward to the base material at a feeding speed higher than usual, the welding wire vigorously collides with the base material
Implementation Method 2
a short circuit is more frequently caused between the welding wire and the base material without interposition of droplets at a wire tip
Data Source
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AI summary
Forward feeding for feeding a welding wire 19 as a consumable electrode in a direction of a workpiece 18 and backward feeding for feeding in an opposite direction to the forward feeding are alternately performed, and the welding wire 19 is fed at a wire feeding speed Vf cyclically changed in a predetermined cycle and at a predetermined amplitude to perform welding by repeating an arc period Ta and a short-circuit period Ts. Provided during forward feeding are a first wire feeding stop step of stopping feeding of the welding wire 19 from a time of an elapse of a half cycle of a change of the wire feeding speed Vf to an elapse of a first feeding stop period Tz1, and a first wire forward feeding step of feeding the welding wire 19 forward at a first feeding speed Vf1 from an elapse of the first feeding stop period Tz1 to an elapse of a predetermined period. The welding wire 19 is fed backward after the elapse of the predetermined period.