Dual-Process Welding Power Supply for Thin-Workpiece Heat Control
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Solution Overview
Problem
Profile pulse welding struggles to effectively weld thinner workpieces as it is typically a hotter process, which can lead to excessive melting, while colder processes are inadequate for materials requiring more energy.
Innovation Solution
A welding power supply system that alternates between hotter and colder processes within a single welding operation, using a controller with a power circuit and feedback circuit to switch between processes like pulse, spray, and short circuit MIG, allowing for controlled heat input and penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hotter process like profile pulse welding is used, then penetration and melting capability are improved, but excessive melting occurs on thinner workpieces
Solution Approach 1:
The welding system alternates periodically between hotter process (profile pulse) and colder process (short circuit or spray) modes. The controller switches between these processes in a cyclic manner, allowing the weld pool to receive intense heating during the hotter process phase for penetration, then cool down during the colder process phase to prevent excessive melting, achieving controlled heat input on thin materials
Solution Approach 2:
The system dynamically changes welding parameters by switching between different welding processes. During the hotter process mode, higher current and voltage parameters are applied for deep penetration. During the colder process mode, lower current and voltage parameters are applied to reduce heat input and prevent burn-through on thin workpieces
2Loss of substance
If a colder process is used to weld thin materials, then excessive melting is prevented, but penetration and melting capability are insufficient for materials requiring more energy
Solution Approach 1:
The welding system alternates periodically between colder process (short circuit or spray) and hotter process (profile pulse) modes. The colder process phase controls heat input and prevents excessive melting on thin materials, while the hotter process phase provides intense heating for adequate penetration and melting capability when needed
Solution Approach 2:
The system dynamically adjusts parameters by switching processes. During colder process mode, lower current and voltage maintain controlled heat input. During hotter process mode, higher current and voltage parameters are applied to provide sufficient penetration and melting capability for the specific material thickness and type
3Shape
If profile pulse welding is used, then a layer dime appearance is achieved, but the process is ineffective for thinner workpieces
Solution Approach 1:
The welding system combines multiple welding processes (profile pulse, short circuit, spray) into a single multi-functional system. This allows the same welding power supply to achieve layer dime appearance on thicker materials using profile pulse, while automatically switching to colder processes for thin materials, making the system universally applicable across different material thicknesses and types
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
Enables the creation of welds with a 'layer dime' appearance, suitable for both thin materials and higher melting requirements, by effectively alternating between hotter and colder processes to control heat and reduce spatter.
Implementation Method 1
The power circuit receives input power and provides welding type output power... alternating between hotter and colder processes to control heat input
Implementation Method 2
Pulse welding, as used herein, includes welding with output power that is generally pulsed, at a controllable frequency, between a greater peak and a lesser background, and pulse welding is performed in an arc state
Data Source
AI summary
A method and apparatus for providing welding-type power that alternates between at least a hotter and a colder process is disclosed.