Arc Welding Torch Speed Control for Bead Continuity
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Solution Overview
Problem
Existing arc welding systems face issues with abnormal welding states and intermittent unwelded portions due to consumable electrode feeding failures, leading to suboptimal bead formation and reduced welding quality.
Innovation Solution
An arc welding system that includes a feeder, power source, welding controller, robot, and detector to alternate between short-circuit and arc states, with a determiner that adjusts the welding torch's speed and movement based on the duration of the arc state to prevent abnormal welding by decelerating or stopping the torch when predetermined periods elapse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding torch moves at a constant speed along the welding line, then the welding process is simple and efficient, but abnormal welding states and intermittent unwelded portions occur due to consumable electrode feeding failures
Solution Approach 1:
The welding torch speed is changed from constant to variable based on the detected state of the consumable electrode. When feeding failure is detected (arc state persists without transitioning to short-circuit state), the speed is automatically adjusted to prevent abnormal welding, thus maintaining both efficiency and quality.
Solution Approach 2:
A detection mechanism monitors the welding state by detecting whether the consumable electrode is properly fed and making contact with the workpiece. This feedback information is used to control the welding torch speed, creating a closed-loop system that prevents defects while maintaining productivity.
2Reliability
If the welding process continuously monitors electrode feeding state and adjusts torch speed, then welding quality improves, but the system complexity increases
Solution Approach 1:
The detection system uses electrical state monitoring (detecting arc state versus short-circuit state) instead of complex mechanical sensors to monitor electrode feeding. This electrical-based detection method simplifies the overall system while effectively identifying feeding failures.
Solution Approach 2:
The welding system uses its own electrical characteristics (arc state detection) to monitor its own operation status. The detection leverages the inherent electrical behavior during welding phases, eliminating the need for separate complex monitoring hardware.
3Manufacturing precision
If the welding torch decelerates or stops based on arc state duration, then intermittent unwelded portions are prevented, but welding productivity decreases
Solution Approach 1:
The system detects the arc state and predicts potential feeding failure before it causes visible defects. By taking preliminary action (decelerating or stopping the torch) when the arc state persists beyond a threshold, the system prevents unwelded portions while minimizing interruption to overall productivity.
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 approach minimizes the occurrence of discontinuous beads and other abnormal formations, thereby improving welding quality and reducing the need for manual intervention by automatically adjusting the welding process in response to potential feeding failures.
Implementation Method 1
The power source is configured to supply power to between the consumable electrode and a to-be-welded object
Data Source
AI summary
An arc welding system includes a feeder to feed a consumable electrode to a welding torch. A power source supplies power to between the electrode and an object. A welding controller controls the feeder and the power source to cause a short-circuit state and an arc state to repeat between the electrode and the object. A robot moves the welding torch along a welding line. A robot controller controls the robot. A detector detects whether a state between the electrode and the object is the short-circuit state or the arc state. A determiner determines whether a first period or a second period has elapsed since the detector detected the arc state. An instructor instructs the robot controller to decelerate the welding torch when the determiner determines that the first period has elapsed, and to stop the welding torch when the determiner determines that the second period has elapsed.