Arc Welding Wire Feed Control With Intermediate Storage Buffer
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Solution Overview
Problem
The existing arc welding methods that alternate between pulse arc welding and short-circuiting transition arc welding periods face challenges in stably feeding the welding wire with high precision due to frequent and abrupt changes in feeding speed and direction, leading to variations in average feeding speed and deteriorated welding quality.
Innovation Solution
An arc welding method employing push-pull feeding control with intermediate wire storage, where the welding wire is compensated based on storage amount to adjust feeding speeds during both pulse and short-circuiting transition arc welding periods, ensuring stable and precise wire feeding by compensating wave form parameters of pull feeding speed during short-circuiting transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If push-pull feeding control is used to alternate between forward feeding during pulse arc welding and forward/backward feeding during short-circuiting transition arc welding, then the welding method can achieve scale-like beads with good appearance and control heat input, but the feeding speed and direction change frequently and abruptly causing unstable wire feeding and deteriorated welding quality
Solution Approach 1:
The patent introduces an intermediate wire storage as a buffer between the push side feeding motor and pull side feeding motor. This intermediate storage acts as a mediator that decouples the frequent speed and direction changes required for quality welding from the wire feeding system, allowing the motors to operate more smoothly while still achieving the necessary feeding patterns for pulse arc and short-circuiting transition arc welding.
Solution Approach 2:
The patent implements feedback control by detecting the wire storage amount in the intermediate wire storage and using this information to compensate control the push side feeding motor or pull side feeding motor. This feedback mechanism monitors the wire consumption and storage status, adjusting the feeding speeds to maintain stable average feeding speed despite the alternating welding modes, thereby ensuring both welding quality and feeding stability.
2Adaptability or versatility
If the forward feeding and backward feeding periods are switched in synchronization with short-circuiting period and arc period, then the welding process can be controlled, but the average feeding speed varies when welding conditions change, causing variation in deposition amount and deteriorated welding quality
Solution Approach 1:
The patent uses feedback control where the wire storage amount detected from the intermediate wire storage is fed back to compensate control the feeding motors. This ensures that even when welding conditions such as welding voltage or projection length vary, the average feeding speed is maintained at a constant value, ensuring consistent deposition amount and welding quality.
Solution Approach 2:
The patent dynamically adjusts the push feeding speed or pull feeding speed based on the detected wire storage amount. By changing the feeding speed parameters in response to storage level variations, the system maintains stable average feeding speed and consistent deposition characteristics across different welding conditions.
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 stabilizes the feeding of the welding wire with high precision, maintaining consistent average feeding speeds and improving welding quality by compensating for variations in wire storage amounts and welding conditions.
Implementation Method 1
a period to forward feed a welding wire and perform the pulse arc welding and a period to forward/backward feed a welding wire and perform the short-circuiting transition arc welding
Data Source
AI summary
Welding is performed by alternately switching a pulse arc welding period (where welding is performed by forward feeding a welding wire by a rotation for the forward feeding of a push side feeding motor and a rotation for the forward feeding of the pull side feeding motor and feeding a peak current and a base current) and a short-circuiting transition arc welding period (welding is performed by forward/backward feeding the welding wire by the rotation for the forward feeding of the push side feeding motor and a rotation for the forward/backward feeding of the pull side feeding motor and feeding a short-circuiting current and an arc current). During the short-circuiting transition arc welding period, a forward feeding peak value Wsp and/or a backward feeding peak value Wrp of a pull feeding speed Fw are compensation-controlled based on a wire storage amount of an intermediate wire storage.