Arc Welding Wire Feeding Stability via Pull-Side Rate Feedback
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Solution Overview
Problem
In arc welding using a push-pull feeding control system, the feeding state of the welding wire becomes unstable due to changes in feeding resistance, leading to phase differences between the pull feeding-rate setting signal and the actual pull feeding rate, affecting the welding quality.
Innovation Solution
An arc welding control method that detects the average feeding rate of the pull-side feeding motor and corrects the push feeding-rate setting value to match the detected average, ensuring the push-side feeding motor's rate equals the pull-side's average rate, thereby stabilizing the welding wire feeding state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the push-side feeding motor performs constant feeding-rate operation, then the feeding path is simplified and control is easier, but the feeding state becomes unstable when feeding resistance changes
Solution Approach 1:
The patent introduces a feedback mechanism where the actual feeding rate of the pull-side feeding motor is detected and compared with the push feeding-rate setting value. The feeding error is calculated and used to correct the push feeding-rate setting value dynamically, ensuring stable feeding state even when feeding resistance changes.
Solution Approach 2:
The patent dynamically adjusts the push feeding-rate setting value based on the detected feeding error and the relationship between push and pull feeding rates. This parameter change allows the system to adapt to varying feeding resistance conditions while maintaining stable feeding.
2Manufacturing precision
If the pull-side feeding motor alternates forward and reverse feeding periodically, then welding quality is improved through short-circuiting and arc periods, but phase difference occurs between setting signal and actual feeding rate
Solution Approach 1:
The patent detects the actual feeding rate of the pull-side feeding motor during periodic forward and reverse feeding operations. By comparing this actual rate with the setting signal, the system calculates feeding error and corrects the push feeding-rate setting value, eliminating phase differences and ensuring synchronization.
3Adaptability or versatility
If feeding resistance changes during welding, then adaptation to varying conditions is necessary, but the push feeding-rate setting value becomes inaccurate
Solution Approach 1:
The patent continuously detects the actual feeding rate and calculates feeding error to dynamically correct the push feeding-rate setting value. This feedback mechanism enables the system to adapt to changing feeding resistance conditions while maintaining accurate feeding rate control.
Solution Approach 2:
The patent makes the push feeding-rate setting value dynamic rather than fixed. It changes based on the detected feeding error and the relationship between push and pull feeding rates, allowing the system to adapt to varying welding conditions and feeding resistance.
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 maintains a stable feeding state of the welding wire even with changing feeding resistance, improving the consistency and quality of the welding process by synchronizing the push and pull feeding rates.
Implementation Method 1
a pull-side feeding motor which alternates a forward feeding rotation and a reverse feeding rotation periodically
Implementation Method 2
generating an arc between the welding wire and base material
Data Source
AI summary
There is provided an arc welding control method of feeding a welding wire according to a push-pull feeding control using a push-side feeding motor which rotates in a forward feeding direction at a feeding rate set to a push feeding-rate setting value and a pull-side feeding motor which alternates a forward feeding rotation and a reverse feeding rotation periodically, and generating short-circuiting periods and arc periods to perform welding. An average feeding rate of the pull-side feeding motor is detected. The push feeding-rate setting value is corrected to the detected average feeding rate of the pull-side feeding motor.