Arc Welding Apparatus Spatter Suppression via Reactor Control
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Solution Overview
Problem
Existing arc welding apparatuses with semiconductor switching devices suffer from energy loss and increased complexity due to large welding currents, leading to inefficient power supply and increased spatter generation.
Innovation Solution
An arc welding apparatus with a transformer-based switching circuit that uses a switching device between the secondary winding terminals, controlled by a circuit that turns off the inverter switching circuit and turns on the switching device when the output voltage reaches a predetermined value, rapidly attenuating the output current to suppress spatter generation, and then reverses energy flow after a short time to rapidly increase the output current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a semiconductor switching device is connected in series to the inverter's secondary side to suppress spatter generation, then spatter generation is reduced, but power supply efficiency deteriorates and structure becomes complicated
Solution Approach 1:
The patent introduces a reactor L as an intermediary element between the inverter and the welding circuit. The reactor suppresses spatter generation by controlling current rise through its inductance, while allowing efficient power transmission. This mediator approach resolves the contradiction by achieving spatter suppression without the energy losses associated with semiconductor switching devices in series.
Solution Approach 2:
The patent replaces the semiconductor switching device (electronic/mechanical component) with a reactor-based inductive control system. By using the natural inductive properties of the reactor to control current rise, the system eliminates the need for active switching devices, thereby improving power supply efficiency while maintaining spatter suppression functionality.
2Object-generated harmful factors
If a semiconductor switching device is connected in series to the inverter's secondary side to suppress spatter generation, then spatter generation is reduced, but device structure becomes complicated
Solution Approach 1:
The reactor L serves as a passive intermediary component that simplifies the overall device structure. Instead of requiring complex semiconductor switching circuits with cooling devices and control systems, the patent uses a simple reactor to achieve spatter suppression, thereby reducing device complexity while maintaining the desired functionality.
3Power
If the output current is increased to improve welding performance, then welding capability is enhanced, but spatter generation increases
Solution Approach 1:
The patent employs dynamic current control through the reactor's inductive properties. The reactor allows the output current to rise gradually rather than abruptly, enabling high welding current to be achieved while controlling the rate of current increase. This dynamic approach prevents spatter generation during arc initiation while maintaining high welding capability during steady-state operation.
Solution Approach 2:
The patent utilizes periodic switching of the inverter to control current delivery. By switching the inverter on and off in controlled cycles, the system can deliver high power for welding while using the reactor to smooth current transitions. This periodic action allows high welding capability without the continuous high current that causes spatter.
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 solution reduces energy loss, improves power supply efficiency, and effectively suppresses spatter generation by rapidly attenuating the output current, while maintaining a simplified structure without the need for a semiconductor switching device.
Implementation Method 1
a transformer provided with a primary winding and a secondary winding, the primary winding being connected to the output side of the inverter and smoothing a rectification output rectified by the rectification circuit
Data Source
AI summary
An arc welding apparatus includes: a switching device connected to both terminals of a secondary winding of a transformer whose opposite primary winding serves as a smoothing reactor on an inverter's secondary side; an output voltage detector detecting an output voltage between a welding wire and a workpiece; and a control circuit controlling the switching device and a circuit on the inverter's primary side. The control circuit includes: a first control portion that turns off the circuit on the inverter's primary side and turns on the switching device when the output voltage detected by the output voltage detector rises to a first predetermined voltage; and a second control portion that turns on the circuit on the inverter's primary side and turns off the switching device after a lapse of a predetermined time after the switching device is turned on.