Arc Welding Apparatus Frequency Control for Penetration Depth
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Solution Overview
Problem
Existing arc welding apparatuses face challenges in achieving increased penetration depth while minimizing the consumption of welding consumables, as higher electric current leads to increased consumable usage.
Innovation Solution
An arc welding apparatus that includes a welding-condition acquirer, a heat-input calculator, a frequency setter, and a driver, which repeatedly generates short circuit and arc conditions by adjusting the frequency and wire feeding speed to control heat input without significantly increasing consumable consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If electric current is increased to increase heat input and penetration depth, then penetration depth is improved, but consumption of welding consumable increases
Solution Approach 1:
The welding apparatus employs periodic short circuit conditions combined with periodic arc conditions instead of continuous arc welding. By repeatedly generating short circuits during the wire feeding process, the system creates periodic melting and pushing actions that enhance penetration depth without requiring continuously high current levels, thereby reducing overall consumable consumption while maintaining effective weld penetration.
2Use of energy by moving object
If frequency of short circuit and arc conditions is decreased to increase heat input per cycle, then heat input is improved, but welding speed decreases
Solution Approach 1:
The system dynamically adjusts multiple parameters including wire feeding speed, electric current amplitude, and frequency of short circuit generation to optimize the balance between heat input and welding speed. By changing these parameters in coordination, the apparatus can maintain high welding speed while ensuring sufficient heat input for adequate penetration depth through the periodic short circuit mechanism.
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 allows for controlled heat input and reduced consumable usage by extending the cycle duration of short circuit and arc conditions, thereby enhancing penetration depth without excessive consumable consumption.
Implementation Method 1
an arc welding apparatus in practical use repeatedly advances and retreats a welding consumable with respect to a workpiece so as to perform welding while periodically generating a short circuit condition and an arc condition
Implementation Method 2
advances a welding consumable to generate a short circuit condition and then further advances the welding consumable until a predetermined time passes. This apparatus allows pushing a fusion portion by the welding consumable instead of increasing the electric current
Data Source
AI summary
An arc welding apparatus includes: a welding-condition acquirer configured to acquire a welding condition; a heat-input calculator configured to calculate a required heat input corresponding to the welding condition; a frequency setter configured to set a smaller frequency for a short circuit condition and an arc condition corresponding to an increase in the required heat input; and a driver configured to repeatedly perform a process at the frequency, the process including advancing and retreating a welding consumable with respect to a workpiece to generate the short circuit condition and the arc condition.