Arc Welding Control Method for Reducing Spatter and Voltage
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Solution Overview
Problem
Conventional arc welding methods struggle to reduce welding voltage, leading to uneven bead widths and increased heat input, which causes fused metal to drop in gap welding operations, limiting welding speed and productivity.
Innovation Solution
An arc welding control method that alternately repeats short circuit and arc periods, with a higher welding output current just after arc recurrence and a sudden decrease in current before recurrence, controlled by a system comprising a welding current detect part, voltage detect part, short circuit arc judge part, setting part, arc initial control part, drive part, and timer part, to set and control the welding output current and voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If constant current control is carried out after passage of a given time starting from arc recurrence time, then droplet formation is stabilized and spatters are reduced, but arc occurrence time cannot be reduced and welding voltage cannot be lowered
Solution Approach 1:
The patent applies dynamics by making the welding current control flexible and adaptive rather than static. The control system dynamically adjusts the welding current based on real-time detection of arc recurrence timing, transitioning from fixed constant current control to a dynamic control mode where current values are modified according to the detected arc recurrence pattern, enabling both spatter reduction and welding voltage lowering
Solution Approach 2:
The patent changes the welding current parameter dynamically based on arc recurrence detection. Instead of maintaining a constant current value, the system detects arc recurrence timing and adjusts the current parameter accordingly - increasing current when arc recurrence is detected to stabilize droplet formation and reduce spatters, while otherwise maintaining lower current to reduce welding voltage and heat input
2Productivity
If welding voltage is lowered to increase welding speed, then productivity is improved, but bead width becomes uneven and fused metal drops in gap welding
Solution Approach 1:
The patent employs feedback control by detecting arc recurrence timing and using this information to adjust welding current in real-time. The detection unit monitors arc recurrence, and this feedback signal triggers current adjustment to maintain stable droplet formation and consistent bead width, even when operating at lower welding voltages for increased productivity
Solution Approach 2:
The system takes preliminary action by detecting arc recurrence timing in advance and proactively adjusting the welding current before droplet formation issues occur. This predictive control prevents bead width unevenness and fused metal dropping by preparing the appropriate current level ahead of time based on detected arc patterns
3Productivity
If arc occurrence time is reduced to enhance welding speed, then productivity increases, but conventional control methods cannot achieve this due to constant current control requirements
Solution Approach 1:
The patent replaces complex mechanical timing and current adjustment mechanisms with an electronic detection and control system. Instead of using mechanical timers and switchers to control current during arc recurrence, the system uses electronic detection of arc recurrence timing followed by electronic current adjustment, simplifying the overall control architecture while enabling faster welding speeds
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 welding voltage, allowing for faster welding speeds and reduced heat input, thereby preventing fused metal from dropping and effectively controlling spatters, enhancing productivity and application range in high-speed and gap welding.
Implementation Method 1
generate an arc between a welding wire composed of a consumable electrode and a base metal or a member to be welded to thereby weld the base metal
Data Source
AI summary
An arc welding control method for repeating alternately a short circuit period allowing a welding wire to short circuit with respect to a member to be welded and an arc period allowing arc recurrence and arc discharge to thereby weld the member to be welded, in which a welding output current just after arc recurrence is controlled to be higher than a welding output current just before arc recurrence for a set given period.