Arc Welding Apparatus Pilot Arc Illumination
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Solution Overview
Problem
Existing arc welding apparatuses are complex and expensive due to the use of slit light sources and arc monitors, requiring operators to alternate between the monitor and the base material, leading to poor operability and high-frequency noise generation.
Innovation Solution
An arc welding apparatus with a main power supply circuit, operation switch, and control circuit that uses a pilot arc current to illuminate the welding point and superimposes high-frequency voltage only once after powering on, allowing smooth arc transition and minimizing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a slit light source and arc monitor are used to indicate the welding point, then the welding point visibility is improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the illumination function from a separate slit light source and arc monitor system, and instead integrates it into the power supply circuit itself by generating a pilot arc. This eliminates the need for dedicated illumination devices while maintaining welding point visibility.
Solution Approach 2:
The power supply circuit is designed to perform multiple functions: it generates both the welding arc for material melting and the pilot arc for illumination. By making the power supply circuit multi-functional, the patent eliminates separate illumination devices and reduces overall system complexity.
2Illumination intensity
If an arc monitor is used to display the welding point, then the welding point visibility is improved, but the device complexity and cost increase
Solution Approach 1:
The patent removes the arc monitor from the system entirely. Instead of using a separate monitoring device, the pilot arc generated by the power supply circuit itself provides the necessary illumination, eliminating the need for complex monitoring and display systems.
Solution Approach 2:
The power supply circuit serves itself by generating the pilot arc for illumination. The same circuit that controls the welding arc also provides the illumination function, making the system self-sufficient and eliminating external monitoring equipment.
3Reliability
If high-frequency voltage is continuously superimposed to facilitate arc creation, then the arc start reliability is improved, but high-frequency noise generation increases
Solution Approach 1:
The patent applies high-frequency voltage periodically rather than continuously. It is superimposed only during the initial arc starting phase when needed, and then discontinued. This periodic application maintains arc start reliability while minimizing noise generation during the welding process.
Solution Approach 2:
The high-frequency voltage is applied in advance only during the arc ignition phase to facilitate reliable arc starting. Once the arc is established, the high-frequency component is removed, preventing continuous noise generation while maintaining the preliminary benefit of reliable arc initiation.
4Loss of information
If the operator alternates between looking at the monitor and the base material, then the welding point information is obtained, but the operability deteriorates
Solution Approach 1:
The patent merges the illumination function with the welding arc itself by generating a pilot arc. This combines the welding process and the visualization function into a single light source, allowing the operator to view the welding point directly on the base material without needing to switch between separate monitoring devices.
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 solution provides an inexpensive, operable, and noise-reduced arc welding process with clear visibility of the welding point, ensuring smooth arc transitions and reduced high-frequency noise.
Implementation Method 1
a main power supply circuit adapted to apply an arc voltage between a welding torch and a base material, thereby passing a welding arc current therethrough
Implementation Method 2
a pilot arc current allows a pilot arc to be established to illuminate the base material, thereby allowing an operator to view a welding point on the base material
Implementation Method 3
a high-frequency voltage generating circuit for generating a high-frequency voltage. The control circuit controls the high-frequency voltage generating circuit such that the high-frequency voltage generating circuit generates a high-frequency voltage to be superimposed on the arc voltage
Data Source
AI summary
An arc welding apparatus includes a main power supply circuit for outputting an arc current, a control circuit for controlling the main power supply circuit, and a high-frequency voltage generating circuit for generating a high-frequency voltage. When an operation switch is turned on for a first time since the apparatus is powered on, the control circuit activates the main power supply circuit to output a high voltage, and the high-frequency voltage generating circuit to generate a high-frequency voltage. With the high voltage superimposed on the high-frequency voltage, the control circuit passes a welding arc current through a torch and a base material. The switch is then turned off, and the control circuit passes a pilot arc current through the torch and the base material. The switch is turned on again, and the control circuit activates the main power supply circuit to output a high voltage, thereby allowing smooth arc transition.