Arc Welding Wire Feed Cycling for Stable Short-Circuit Transfer
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Solution Overview
Problem
Consumable electrode type arc welding methods face issues with increased spatter generation and unstable arc stability due to high feeding speeds of the welding wire, leading to frequent short circuits without droplet interposition and elongated short-circuit periods.
Innovation Solution
The method alternates forward and backward feeding of the welding wire with cyclically changing speeds, incorporating feeding stops and controlled speeds to reduce impact and stabilize the short-circuit cycle, ensuring reliable droplet formation and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire feeding speed is increased to maintain productivity, then productivity is improved, but spatter generation increases and arc stability deteriorates
Solution Approach 1:
The patent applies periodic action by cyclically changing the wire feeding speed between a first feeding speed (during arc period) and a second feeding speed (during short-circuit period). This periodic speed variation allows the system to maintain higher average productivity while periodically reducing speed to minimize spatter generation and ensure stable arc operation during critical phases.
Solution Approach 2:
The patent implements dynamics by making the wire feeding speed variable rather than constant. The feeding speed is dynamically adjusted based on the welding state (arc period or short-circuit period), transitioning between different speed levels to optimize both productivity and spatter reduction at different stages of the welding cycle.
2Productivity
If the wire feeding speed is increased to maintain productivity, then productivity is improved, but arc stability deteriorates due to frequent short circuits
Solution Approach 1:
The patent uses periodic action to cyclically adjust wire feeding speed according to the welding state. During arc periods, the first feeding speed maintains productivity, while during short-circuit periods, the second feeding speed (lower than the first) stabilizes the arc by preventing excessive wire advance that would cause frequent short circuits.
Solution Approach 2:
The patent implements feedback control by detecting the welding state (arc or short-circuit condition) and adjusting the wire feeding speed accordingly. The control system monitors the welding process and dynamically modifies the feeding speed to maintain arc stability while preserving overall productivity.
3Productivity
If the wire feeding speed is increased, then productivity is improved, but the short-circuit period elongates causing unstable short-circuit cycle
Solution Approach 1:
The patent applies periodic action by implementing distinct feeding speed phases corresponding to arc periods and short-circuit periods. The lower second feeding speed during short-circuit periods ensures proper droplet formation and timely short-circuit occurrence, preventing elongation of the short-circuit period while maintaining high average productivity through the first feeding speed during arc periods.
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 reduces spatter generation and enhances arc stability by minimizing collision impact and stabilizing the short-circuit cycle, improving welding quality and consistency.
Implementation Method 1
when the welding wire is fed forward to the base material at a feeding speed higher than usual, the welding wire vigorously collides with the base material
Implementation Method 2
a short circuit is more frequently caused between the welding wire and the base material without interposition of droplets at a wire tip
Data Source
AI summary
Forward feeding for feeding a welding wire in a direction of a workpiece and backward feeding for feeding in an opposite direction to the forward feeding are alternately performed, and the welding wire is fed at a wire feeding speed cyclically changed in a predetermined cycle and at a predetermined amplitude to perform welding by repeating an arc period and a short-circuit period. Provided during forward feeding, stopping feeding of the welding wire from a time of an elapse of a half cycle of a change of the wire feeding speed to an elapse of a first feeding stop period, and feeding the welding wire forward at a first feeding speed from an elapse of the first feeding stop period to an elapse of a predetermined period. The welding wire is fed backward after the elapse of the predetermined period.