Arc Welding Wire Feed Control for Stable Startup Transients
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Solution Overview
Problem
During the transient welding period from the start of welding to convergence to a steady welding period, the existing forward/reverse feeding control methods lead to an unstable welding state.
Innovation Solution
An arc welding control method that alternates the feeding rate between forward and reverse feeding periods, with distinct waveform parameters and average values during the transient period, shifting to forward feeding in response to arc periods and reverse feeding in response to short-circuiting periods, and utilizing a push-side feeding motor for accelerated forward feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forward/reverse feeding control is applied during transient welding period, then welding quality is improved, but welding state becomes unstable
Solution Approach 1:
The patent applies preliminary action by implementing a push-side feeding motor that accelerates with an inclination before the main forward/reverse feeding control begins. This preliminary acceleration prepares the welding wire feeding system for the upcoming cyclic control, ensuring smooth transition and preventing instability during the transient welding period. The push-side motor's inclined acceleration profile pre-conditiones the system for the alternating feeding pattern.
Solution Approach 2:
The patent implements dynamics by using a push-side feeding motor that provides variable acceleration with an inclination during the transient period, rather than constant speed feeding. This dynamic adjustment of feeding rate allows the system to adapt to the changing welding conditions during startup, maintaining stability while enabling the quality improvements of forward/reverse feeding control.
2Manufacturing precision
If constant feeding rate is used, then system simplicity is maintained, but welding quality cannot be improved
Solution Approach 1:
The patent applies segmentation by dividing the feeding control into two independent parts: a push-side feeding motor for forward feeding and a pull-side feeding motor for reverse feeding. This segmentation allows each motor to be optimized for its specific function and enables the complex forward/reverse feeding pattern without requiring a single complex control system. The segmented approach maintains relative system simplicity while achieving improved welding quality.
Solution Approach 2:
The patent merges two feeding mechanisms (push-side and pull-side motors) to achieve the forward/reverse feeding control. By combining these two simpler mechanisms working in coordination, the system achieves the complex feeding pattern needed for improved welding quality without the complexity of a single sophisticated control system. The merged system leverages the advantages of both push and pull feeding approaches.
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 stabilizes the welding state during the transient period by adjusting feeding rates and using a push-side motor for enhanced control, ensuring smoother transition to a steady welding state.
Implementation Method 1
generating an arc between the welding wire and base material
Implementation Method 2
both the welding wire and the base material are mostly placed in a welding state in which a short-circuiting period and an arc period are alternately repeated
Data Source
AI summary
There is provided an arc welding control method of performing a forward/reverse feeding control of alternating a feeding rate of a welding wire between a forward feeding period and a reverse feeding period, and generating short-circuiting periods and arc periods to perform welding. The welding wire is fed forwardly at a time of staring the welding. The forward/reverse feeding control is started from the reverse feeding period of the welding wire after starting conduction of a welding current.