Arc Welding Wire Feed Compensation for Stable Push-Pull Switching
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Solution Overview
Problem
In arc welding methods that alternately switch between pulse arc welding and short-circuiting transition arc welding periods, the frequent and abrupt changes in feeding speed and direction of the welding wire lead to instability and precision issues in wire feeding.
Innovation Solution
The arc welding method stabilizes wire feeding by compensating the forward and backward feeding speeds based on the wire storage amount in the intermediate wire storage, ensuring precise control during the switching between pulse arc and short-circuiting transition arc welding periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the welding wire feeding speed and direction are frequently switched between forward and backward feeding during pulse arc welding and short-circuiting transition arc welding, then the welding process can be controlled to achieve scale-like beads with good appearance, but the feeding stability and precision deteriorate due to frequent abrupt changes
Solution Approach 1:
The patent implements feedback control by detecting the actual wire storage amount in the intermediate wire storage and comparing it with the target value. Based on the detection result, the feeding speed is dynamically adjusted to maintain stable wire feeding despite frequent switching between forward and backward feeding modes during pulse arc welding and short-circuiting transition arc welding.
Solution Approach 2:
The patent introduces an intermediate wire storage as a buffer between the wire feed motor and the welding torch. This intermediary component temporarily stores welding wire and allows the system to smooth out frequent speed and direction changes, thereby maintaining feeding stability while enabling the rapid switching required for good bead appearance.
2Adaptability or versatility
If the forward feeding period and backward feeding period 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 such as welding voltage and projection length vary, causing deposition amount variation and welding quality deterioration
Solution Approach 1:
The patent uses feedback control to detect the wire storage amount in the intermediate wire storage and dynamically adjusts the feeding speed based on the detection result. This ensures that the average feeding speed remains constant even when welding conditions such as welding voltage and projection length vary, thereby maintaining consistent deposition amount and welding quality.
Solution Approach 2:
The patent implements dynamic speed adjustment by varying the feeding speed according to the detected wire storage amount. The feeding speed is not fixed but is dynamically controlled to compensate for variations in welding conditions, ensuring consistent deposition while adapting to different welding parameters.
3Speed
If push-pull feeding mode is adopted with intermediate wire storage to enable high-speed switching between forward and backward feeding, then the welding process can be controlled during short-circuiting and arc periods, but the system complexity increases
Solution Approach 1:
The patent introduces an intermediate wire storage as a buffer component between the push-pull feeding mechanism and the welding torch. This intermediary allows the system to achieve high-speed switching between forward and backward feeding while isolating the complexity of the switching mechanism from the critical welding zone, thereby enabling rapid control during short-circuiting and arc periods.
Solution Approach 2:
The patent segments the feeding system into distinct functional parts: a push-pull feeding mechanism for high-speed directional switching, an intermediate wire storage for buffering and smoothing, and a welding torch assembly. This segmentation allows each component to perform its specific function optimally while reducing the overall system complexity by distributing functions across separate modules.
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 stable and high-precision feeding of the welding wire, maintaining consistent deposition and improving welding quality by minimizing variations in average feeding speed.
Implementation Method 1
as the feeding mode, the push-pull feeding mode is adopted often
Implementation Method 2
an intermediate wire storage for temporarily storing the welding wire is often provided at a feeding passage
Implementation Method 3
arc welding method to perform welding by alternately switching a pulse arc welding period and a short-circuiting transition arc welding period
Data Source
Figure 1
Figure 2(A)~2(H)
Figure 3(A)~3(G)
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.