Buffered Wire Feeding Control for Stable Arc Welding
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Solution Overview
Problem
Existing arc welding systems face issues with wire feeding speed synchronization and torque control, leading to problems like slipping or buckling of welding wire, especially in high-speed large current welding applications.
Innovation Solution
The implementation of a wire feeding device with speed control for both the first and second feeding parts, along with an intermediate wire feeding source, allows for stable wire feeding by maintaining equal feeding speeds and eliminating the need for precise synchronization and torque adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the push feeder is torque-controlled, then the wire feeding system can handle varying wire path conditions and wire diameters, but the response to abrupt changes in feeding speed is delayed causing wire slipping or buckling
Solution Approach 1:
The wire feeding system is divided into two independent feeding parts (push feeder and pull feeder), each with its own speed control. This segmentation allows each part to operate independently at the required speed without being constrained by torque control limitations, thereby improving response speed while maintaining adaptability through coordinated control.
Solution Approach 2:
The system transitions from static torque control to dynamic speed control where both feeding parts can independently adjust their speeds in real-time. This dynamic control enables the system to respond immediately to abrupt changes in feeding requirements, eliminating the response delay inherent in torque-controlled systems.
2Speed
If speed control is implemented for both feeding parts, then response to wire feeding speed changes is improved, but synchronization between the two feeding parts becomes more complex
Solution Approach 1:
An intermediate wire reservoir is introduced between the two feeding parts to act as a buffer and decoupling element. This intermediary allows the push feeder and pull feeder to operate at different speeds temporarily without causing wire slack or tension issues, thereby simplifying the synchronization requirement while maintaining high response speed.
Solution Approach 2:
The wire reservoir automatically compensates for speed differences between the two feeding parts through its inherent mechanical properties. When speeds differ, the reservoir naturally absorbs or releases wire as needed, eliminating the need for complex active synchronization control systems.
3Adaptability or versatility
If torque adjustment is performed on the push side, then wire feeding can be adapted to different conditions, but the system requires additional adjustment operations and complexity
Solution Approach 1:
The system replaces mechanical torque control with electronic speed control for both feeding parts. This substitution eliminates the need for manual torque adjustment operations while maintaining adaptability through programmable speed control, thereby improving ease of operation without sacrificing versatility.
Data Source
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AI summary
A wire feeding device configured to feed welding wire (W) from a wire feeding source to a welding torch is provided with: an intermediate wire feeding source (41) that is disposed between the wire feeding source and the welding torch and is configured to temporarily store the welding wire (W) fed from the wire feeding source and to feed the stored welding wire (W) to the welding torch; a first feeding part (41d) that feeds the welding wire (W) at the wire feeding source to the intermediate wire feeding source (41); a second feeding part (42) that feeds the welding wire (W) stored in the intermediate wire feeding source (41) to the welding torch; and a feed control unit (5b) that controls speed of feeding the welding wire (W) by each of the first feeding part (41d) and the second feeding part (42).