Arc Welding Control Method Using Reverse Wire Feeding
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Solution Overview
Problem
Existing arc welding methods require cumbersome voltage detection lines and sensitive adjustments to reduce spatter, which are prone to breakage and time-consuming to set up, especially as the welding torch moves.
Innovation Solution
An arc welding control method that alternates wire feeding between forward and reverse feeding, reducing the welding current during the reverse feeding period to generate short-circuiting and arc periods without detecting narrow parts, by starting current reduction at a predetermined reference state of reverse feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If narrow-part detection control is performed to reduce spatter, then spatter generation is reduced, but voltage detection lines are required which are prone to breakage and require frequent adjustment
Solution Approach 1:
The invention extracts and eliminates the voltage detection lines and narrow-part detection mechanism from the welding system. Instead of detecting the narrow part formation, the method uses predetermined timing based on reverse feeding state to reduce welding current, thereby removing the unreliable detection lines while maintaining spatter reduction capability
Solution Approach 2:
The welding system uses its own feeding mechanism and timing information to control current reduction. The reverse feeding state and predetermined timing automatically provide the necessary control signals, making the system self-regulating without external detection lines or additional sensors
2Object-generated harmful factors
If narrow-part detection control is performed to reduce spatter, then spatter generation is reduced, but detection sensitivity requires frequent adjustment especially when welding torch moves
Solution Approach 1:
The invention introduces dynamic timing adjustment based on the reverse feeding state. The current reduction timing is determined by the actual feeding rate and reverse feeding duration, automatically adapting to changes in welding conditions and torch position without requiring manual sensitivity adjustment
Solution Approach 2:
The system uses feedback from the feeding rate sensor and reverse feeding state to automatically determine the optimal timing for current reduction. This closed-loop approach eliminates the need for manual adjustment of detection sensitivity while maintaining effective spatter control
3Manufacturing precision
If forward and reverse feeding are alternated to control arc regeneration, then welding quality is improved, but the control system becomes more complex
Solution Approach 1:
The invention employs periodic alternation between forward feeding and reverse feeding at predetermined intervals. This rhythmic control pattern simplifies the overall system architecture by using time-based control logic rather than complex real-time detection and adjustment mechanisms, while still achieving high welding quality through controlled arc regeneration
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 reduces spatter generation efficiently without the need for voltage detection, maintaining a small current value during the arc period, thus enhancing welding quality and efficiency.
Implementation Method 1
generating an arc between the welding wire and base material
Implementation Method 2
welding is performed by feeding a welding wire as a consumable electrode at a constant feeding rate and 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 to generate a short-circuiting period and an arc period in a manner that shifting to the arc period is performed by reducing a welding current in the reverse feeding during the short-circuiting period. Reduction of the welding current is started from a time where a state of the reverse feeding reaches a predetermined reference state.