Dual Wire Feeder Speed Control to Prevent Welding Voltage Drop
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing wire feeding systems for welding face issues with voltage drops during rapid changes in feeding speed, leading to potential power supply failures and microcomputer voltage instability, which can cause errors and disrupt the welding process.
Innovation Solution
A wire feeding system with a controller that gradually changes the speed command for the second feeder over time when the amount of change is outside a predetermined range, preventing voltage drops and ensuring stable power supply to the microcomputer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the feeding speed of the welding wire is greatly changed to respond to switching welding conditions or arc break process, then the adaptability of the welding system is improved, but the power supply voltage drops due to transient response of the motor
Solution Approach 1:
The system dynamically adjusts the speed command based on the current feeding speed. When the welding wire feeding speed needs to change, the controller calculates the difference between the current speed and target speed, and only issues a speed change command when this difference exceeds a predetermined threshold. This dynamic adjustment prevents unnecessary rapid changes that would cause voltage drops while still allowing timely responses to welding condition changes.
Solution Approach 2:
The controller continuously monitors the current feeding speed of the welding wire and uses this feedback to determine whether to issue a speed change command. By comparing the current speed with the target speed and evaluating the magnitude of the difference, the system provides feedback control that prevents excessive speed changes and the associated voltage drops, while maintaining appropriate responsiveness to welding conditions.
2Device complexity
If a single power supply is shared between motors and microcomputer to reduce size and weight, then the device complexity is reduced, but the voltage stability for the microcomputer becomes problematic during motor transient response
Solution Approach 1:
The system dynamically controls the motor speed changes by evaluating the difference between current and target feeding speeds. This dynamic control prevents sudden large current draws during motor transient response, thereby maintaining voltage stability for the microcomputer while continuing to use the simplified single shared power supply configuration.
Data Source
AI summary
A wire feeding system includes a first feeder provided with a first feeding motor that feeds a wire in a wire feeding direction, a second feeder spaced apart from the first feeder in the wire feeding direction and provided with a second feeding motor that feeds the wire in the wire feeding direction, and a controller that controls the rotation speed of the first feeding motor based on a first speed command and controls the rotation speed of the second feeding motor based on a second speed command. The controller gradually changes the second speed command over time when an amount of change of the second speed command is not within a predetermined range.