Arc Welding Wire Feeding Control for Phase Difference Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In arc welding, a phase difference between the feeding-rate setting signal and the actual feeding rate occurs due to transient characteristics of the feeding motor and changing feeding resistance, affecting the average welding current and quality.
Innovation Solution
An arc welding control method that detects the average feeding rate and adjusts the forward and reverse feeding amplitudes and periods to maintain a constant average feeding rate, correcting the feeding rate pattern automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forward feeding and reverse feeding are alternated periodically to improve welding quality, then welding quality is improved, but phase difference between feeding-rate setting signal and actual feeding rate occurs due to transient characteristics of feeding motor and changing feeding resistance
Solution Approach 1:
The patent implements a feedback control mechanism where the average feeding rate is continuously detected and compared with the target average feeding rate. Based on the detection result, the forward feeding amplitude, reverse feeding amplitude, forward feeding period, or reverse feeding period is automatically adjusted to correct phase differences and maintain stable welding quality despite transient characteristics of the feeding motor and changing feeding resistance.
2Adaptability or versatility
If feeding resistance changes during welding, then welding conditions vary, but average feeding rate becomes unstable affecting welding quality
Solution Approach 1:
The patent employs dynamic adjustment of feeding parameters by continuously monitoring the average feeding rate and automatically modifying the forward feeding amplitude, reverse feeding amplitude, forward feeding period, or reverse feeding period in real-time. This dynamic control compensates for changing feeding resistance and maintains consistent average feeding rate despite varying welding 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 method stabilizes the welding quality by maintaining a constant average feeding rate despite changes in feeding resistance, ensuring consistent welding performance.
Implementation Method 1
generating an arc between the welding wire and base material
Data Source
AI summary
There is provided an arc welding control method of alternating feeding of a welding wire between forward feeding and reverse feeding periodically according to a feeding rate pattern constituted of a forward feeding amplitude, a reverse feeding amplitude, a forward feeding period and a reverse feeding period, stored in correspondence to an average feeding rate setting value, and generating short-circuiting periods and arc periods to perform welding. An average feeding rate of the welding wire is detected, and at least one of the forward feeding amplitude, the reverse feeding amplitude, the forward feeding period or the reverse feeding period is changed so that the detected average feeding rate equals the average feeding rate setting value, thereby automatically correcting the feeding rate pattern.