Arc Welding Tracking Control Using Weaving-Electrical Deviation Modeling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional arc-tracking welding methods face challenges in achieving accurate tracking control due to varying sensitivity, which makes it difficult to determine the optimal feedback gain, leading to unstable control performance.
Innovation Solution
The method involves a consumable electrode type welding device with a weaving function that uses a physical model to establish a relationship between the weaving position and electrical elements like welding resistance, voltage, or current, allowing for precise deviation calculation and control through a control processing unit, moving mechanism, and measurement units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If feedback gain is increased to improve tracking accuracy when sensitivity is low, then tracking precision improves, but control stability deteriorates when sensitivity is high
Solution Approach 1:
The feedback gain is made dynamically adjustable based on the detected sensitivity level. The control system automatically increases feedback gain when sensitivity is low to improve tracking accuracy, and reduces it when sensitivity is high to maintain stability, thereby resolving the contradiction between tracking precision and control stability across varying welding conditions
Solution Approach 2:
The system changes the feedback gain parameter according to the detected sensitivity variations. By monitoring welding conditions and adjusting the feedback gain parameter accordingly, the system adapts to different sensitivity levels, achieving both high tracking accuracy when needed and stable control when sensitivity is high
2Stability of the object's composition
If feedback gain is determined based on high sensitivity cases, then control stability is maintained, but tracking accuracy deteriorates due to insufficient feedback gain
Solution Approach 1:
Rather than using a fixed feedback gain determined for high sensitivity cases, the system dynamically adjusts the feedback gain based on real-time sensitivity detection. This allows the system to use higher feedback gains when sensitivity is low (improving tracking accuracy) while maintaining stability when sensitivity is high
3Adaptability or versatility
If sensitivity varies with welding conditions, then adaptability to different welding states improves, but determination of optimal feedback gain becomes difficult
Solution Approach 1:
The system implements a feedback mechanism that detects sensitivity variations based on welding conditions and automatically adjusts the feedback gain accordingly. This feedback loop simplifies the determination of optimal feedback gain by using real-time sensitivity information, allowing the system to adapt to different welding conditions without complex manual calibration
Solution Approach 2:
The control system performs self-adjustment of the feedback gain based on its own detection of sensitivity variations. By monitoring welding conditions and automatically modifying its control parameters, the system serves itself, eliminating the need for external intervention or complex determination procedures
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 enables more accurate tracking control by using a relationship-based method instead of relying solely on differences in current or resistance values, stabilizing the tracking process and improving control performance.
Implementation Method 1
detecting a deviation between a weaving center and a welding line based on the detected change amount of the resistance value
Implementation Method 2
causing a high frequency component to be superimposed on a welding current to be supplied to the consumable electrode
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In an arc-tracking welding method and a welding device of the present invention, a deviation amount between a weaving center and a welding line is obtained based on a first relationship and a second relationship. The first relationship is a relationship between a weaving position and any one element of three electrical first to third elements related to Ohm's law, the relationship being obtained based on a physical model of an arc welding phenomenon and being associated with the deviation amount. The second relationship is a relationship between the weaving position and the element, the relationship being obtained based on the element in welding power.