Arc Welding Wire Buffer Recovery After Abnormal Feed Stops
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire feeding devices in arc welding systems face issues with abnormal stops due to fluctuations in the buffer amount of welding wire between the push feeder and the pull feeder, leading to instability in weldability and requiring manual intervention to restore normal operation.
Innovation Solution
A wire feeding device with a wire buffer, detection unit, and feed control unit that adjusts the feeding speed of the first and second feeding parts to maintain a predetermined amount of welding wire, allowing for automatic adjustment and restoration of the buffer amount through user instructions, thereby preventing abnormal stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire buffer is introduced to stabilize welding wire feeding, then welding stability is improved, but device complexity increases due to additional components and control mechanisms
Solution Approach 1:
A wire buffer is introduced as an intermediary component between the push feeder and pull feeder to stabilize welding wire feeding. The wire buffer temporarily stores welding wire and releases it at a controlled rate, acting as a mediator that decouples the synchronization requirements between the two feeders and prevents wire loosening or stretching.
Solution Approach 2:
A detection unit monitors the buffer amount of welding wire in the wire buffer and provides feedback to the control unit. The control unit adjusts the rotation speeds of the push feeder and pull feeder based on this feedback to maintain the buffer amount within a predetermined range, thereby stabilizing welding wire feeding automatically.
2Ease of operation
If manual intervention is required to restore buffer amount after abnormal stop, then operation simplicity is maintained, but productivity decreases due to operational interruptions
Solution Approach 1:
The system performs self-service by automatically restoring the wire buffer amount after an abnormal stop. When the detection unit detects that the buffer amount is outside the predetermined range following a stop, the control unit automatically adjusts the rotation speeds of the feeders to restore the buffer amount to the appropriate range, eliminating the need for manual intervention and preventing abnormal stops.
3Productivity
If high speed welding wire feeding is implemented, then productivity is improved, but sensitivity to timing synchronization increases leading to feeding instability
Solution Approach 1:
The wire buffer performs preliminary action by pre-storing welding wire before it is needed at high speed. This allows the pull feeder to retrieve wire from the buffer without requiring precise synchronization with the push feeder during high-speed operation, reducing sensitivity to timing differences and maintaining feeding stability.
Data Source
AI summary
The wire feeding device that feeds welding wire W from the wire source to the welding torch is disposed between the wire source and the welding torch and is configured to temporarily accommodate the welding wire W fed from the wire source and to feed the accommodated welding wire W to the welding torch. In the case where feeding of welding wire W is abnormally stopped, if the acceptance unit accepts instructions for increasing or decreasing, the wire feeding device controls the speed of feeding welding wire W fed by the first feeding part or the second feeding part so that a difference is generated in the feeding speed of the first feeding part and the second feeding part and the accommodated amount of welding wire W is in a range from the lower limit of normal to an upper limit of normal.