Arc Welding Start Control for Touch Start Detection and Position Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional arc welding methods often result in start failures and tip welding due to touch start conditions, leading to deteriorated welding quality, as existing avoidance methods are inadequate in ensuring the desired distance between the wire and workpiece.
Innovation Solution
A control device comprising an input/output unit, a measuring unit, and a processing unit that measures the time from the welding start command to arc generation and performs warning or modification processing when this time or its statistic is below a threshold, adjusting the welding start position to prevent touch starts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If touch start welding is performed to improve welding speed and simplify operation, then productivity increases, but welding quality deteriorates due to start failures and tip welding
Solution Approach 1:
The system performs preliminary detection of touch start conditions before welding begins by measuring the time from welding start command to arc generation. When touch start is detected (time equals or less than first threshold), the system executes preliminary corrective actions including reverse wire running and position correction before resuming normal welding, thereby preventing quality deterioration while maintaining productivity
Solution Approach 2:
The system implements feedback control by continuously monitoring the time from welding start command to arc generation signal. This feedback mechanism detects touch start conditions in real-time and triggers appropriate corrective measures, enabling the system to maintain both high productivity and welding quality through automatic adjustment
2Manufacturing precision
If reverse wire running is performed to avoid touch start and improve welding quality, then welding quality improves, but the desired distance between tip and workpiece cannot be obtained and welding continues as is
Solution Approach 1:
The system performs position correction as a preliminary action after detecting touch start and executing reverse wire running. By calculating the required correction distance and adjusting the wire feed position before resuming welding, the system ensures the desired tip-to-workpiece distance is restored, improving both quality and reliability
Solution Approach 2:
The system replaces manual distance adjustment with automated position correction based on time measurement feedback. The control device automatically calculates and executes the necessary position adjustment after touch start detection, eliminating the need for manual intervention and ensuring consistent distance control
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 improves welding quality by effectively preventing touch starts and ensuring a proper distance between the welding wire and workpiece, enhancing the overall quality of the welding process.
Implementation Method 1
a power supply unit configured to supply power for arc welding to the welding wire
Data Source
AI summary
A control device according to an embodiment comprises: an input/output unit; a measurement unit; and a processing unit. The input/output unit configured to output first information instructing start of welding to an arc welder and receive input of second information indicating generation of an arc by the arc welder. The measurement unit configured to measure a time from the output of the first information to the input of the second information. The processing unit configured to perform predetermined processing when the time or a statistic of the times is equal to or less than a first threshold.