Brazing Interruption Control for Uniform Bead Resumption
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Solution Overview
Problem
Brazing systems face interruptions, leading to shape defects such as unevenness in the formed bead, as the brazing process is not effectively managed when the brazing material supply is interrupted.
Innovation Solution
A control device that controls a heating device and a movement machine to retract the brazing material tip from the heating position during interruptions, and then resumes brazing by advancing the heating device or base material to the interruption position, ensuring the brazing material tip reaches the heating position simultaneously, thus preventing shape defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing is interrupted due to brazing material supply issues, then brazing process stops, but shape defects such as unevenness occur in the formed bead
Solution Approach 1:
The control device performs preliminary actions by detecting brazing material supply status in advance and controlling the brazing head to retract before complete supply interruption occurs. This preventive retraction avoids the formation of shape defects like unevenness in the bead, thereby maintaining both process reliability and manufacturing precision during interruptions.
2Manufacturing precision
If brazing material tip is retracted from heating position during interruption, then shape defects are prevented, but brazing process is interrupted
Solution Approach 1:
The control device implements feedback control by continuously monitoring brazing material supply status and automatically adjusting the brazing head position in response. When supply interruption is detected, the system triggers retraction and subsequent resumption actions, enabling automatic adaptation that prevents defects while minimizing manual intervention and overall time loss.
Solution Approach 2:
The system temporarily discards the current brazing position by retracting the brazing head during interruption, then recovers by resuming brazing at the interruption position. This discard-recover mechanism prevents defect formation while the control device optimizes the resumption timing to minimize total process time loss.
3Device complexity
If brazing is resumed without coordinating heating device position and brazing material tip position, then equipment simplicity is maintained, but shape defects occur due to timing mismatch
Solution Approach 1:
The control device changes operational parameters by coordinating the positions and movement timing of the heating device and brazing material tip during resumption. By adjusting these parameters to ensure simultaneous arrival at the interruption position, the system maintains relatively simple equipment while achieving precise bead formation without shape defects.
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 solution allows for seamless resumption of brazing, preventing shape defects like unevenness and reducing equipment damage, while optimizing the work cycle by accurately timing the refeeding of the brazing material, ensuring a smooth bead formation along the work path.
Implementation Method 1
a heating device for a brazing material
Data Source
AI summary
The control device includes a brazing controller configured to control a brazing material moving mechanism so as to retract a tip of a brazing material from a heating position to interrupt the brazing, during execution of the brazing, and a movement controller configured to, when the brazing is interrupted, control a movement machine so as to retract a heating device or a base material in a direction opposite to a movement direction during the execution of the brazing, and subsequently advance the heating device or the base material in the movement direction again. The brazing controller resumes the brazing by controlling the brazing material moving mechanism so as to cause the tip of the brazing material to reach the heating position at the same time when the heating device or the base material advanced by the movement controller reaches an interruption position at which the brazing is interrupted.