Arc Welding Wire Feeding With Intermediate Storage Speed Matching
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Solution Overview
Problem
Existing wire feeding devices in arc welding systems face issues with maintaining stable wire feeding speed, particularly during high-speed welding, due to torque control limitations, leading to problems like slipping or buckling of the welding wire.
Innovation Solution
A wire feeding device with an intermediate wire feeding source and dual speed-controlled feeding parts, where the feed control unit ensures equal feeding speeds and adjusts based on detected wire storage amounts to maintain a predetermined range, eliminating the need for torque adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If torque control is used on the push feeder, then the structure is simple, but the response to wire feeding speed changes is slow causing slipping or buckling
Solution Approach 1:
The patent replaces the torque-controlled mechanical system with a speed-controlled system. The push feeder and pull feeder are both controlled by speed commands from the power supply device, eliminating the response delay inherent in torque control. The push feeder's rotation speed is directly controlled to match the required wire feeding speed, providing high responsiveness without mechanical complexity.
Solution Approach 2:
The patent implements a feedback mechanism where the power supply device receives speed information from the pull feeder and generates corresponding speed commands for the push feeder. This closed-loop control ensures that the push feeder's output speed matches the pull feeder's input speed requirements, preventing wire slipping and buckling while maintaining simple system structure.
2Speed
If speed control is implemented on both feeders, then wire feeding response is high, but synchronization between feeders becomes complex
Solution Approach 1:
The patent uses the power supply device as an intermediary that centralizes the synchronization control. Instead of requiring direct communication and coordination between the push feeder and pull feeder, both feeders receive speed commands from the power supply device. This mediator approach simplifies synchronization by providing a single control source that coordinates both feeders without complex inter-feeder communication.
3Adaptability or versatility
If torque adjustment is required on the push side, then wire feeding can adapt to different conditions, but operation becomes more complex
Solution Approach 1:
The patent changes the control parameter from torque to speed. Instead of adjusting torque levels to adapt to different wire feeding conditions, the system directly controls the rotation speed of the push feeder. This parameter change simplifies operation because speed control is more intuitive and easier to adjust than torque control, while maintaining the same adaptability to different welding conditions through speed variation.
Data Source
AI summary
A wire feeding device configured to feed welding wire from a wire feeding source to a welding torch is provided with: an intermediate wire feeding source that is disposed between the wire feeding source and the welding torch and is configured to temporarily store the welding wire fed from the wire feeding source and to feed the stored welding wire to the welding torch; a first feeding part that feeds the welding wire at the wire feeding source to the intermediate wire feeding source; a second feeding part that feeds the welding wire stored in the intermediate wire feeding source to the welding torch; and a feed control unit that controls speed of feeding the welding wire by each of the first feeding part and the second feeding part.