Arc Welding Wire Retraction for Stable Short-Circuit Cycles
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Solution Overview
Problem
Arc welding techniques face instability in the welding current cycle due to short-circuits between the welding wire and the base material, leading to deteriorated bead appearance.
Innovation Solution
An arc welding method and device that detect short-circuits and adjust the feeding speed of the welding wire from a positive to a negative feeding speed, along with controlling the welding current to maintain a stable cycle, preventing the instability caused by short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pulsed-arc welding is controlled to increase welding current when short-circuit is detected, then droplet transfer is improved, but the welding current cycle becomes unstable
Solution Approach 1:
The patent applies preliminary action by changing the welding wire feeding speed to a negative side immediately when a short-circuit is detected, before the short-circuit naturally opens. This proactive measure prevents the instability that would otherwise occur during the short-circuit period, maintaining consistent welding current cycles and improving bead appearance.
2Manufacturing precision
If welding current is increased during short-circuit, then droplet generation is enhanced, but cycle consistency deteriorates
Solution Approach 1:
The patent applies preliminary anti-action by counteracting the harmful effect of extended short-circuit duration through negative feeding speed adjustment. By moving the welding wire away from the base material immediately upon detecting a short-circuit, the method prevents the short-circuit from persisting, thereby maintaining manufacturing precision without time loss.
3Reliability
If welding wire feeding speed is maintained at positive speed during short-circuit, then continuous welding is preserved, but wire buckling risk increases
Solution Approach 1:
The patent applies inversion by reversing the normal positive feeding speed to a negative feeding speed when a short-circuit is detected. This opposite action prevents the welding wire from buckling by pulling it away from the base material, while the automated control ensures welding process continuity is maintained through proper timing and current adjustment.
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 effectively prevents the instability of the welding current cycle, promotes the opening of short-circuits, and reduces the risk of buckling by adjusting the feeding speed, thereby maintaining a consistent welding current cycle and improving weld quality.
Implementation Method 1
a welding current in a pulse form alternately including a peak current and a base current smaller than the peak current is caused to flow through the welding wire and the base material to generate an arc between the welding wire and the base material to weld the base material
Data Source
AI summary
Arc welding, in which a welding wire serving as a consumable electrode is fed toward a base material and a welding current alternately including a peak current and a base current is caused to flow through the welding wire and the base material, is performed such that after a short-circuit between the welding wire and the base material is detected, a feeding speed of the welding wire is changed from a first feeding speed to a second feeding speed that is on a negative side from the first feeding speed when a speed in a direction in which the welding wire is fed toward the base material is defined as positive.