Dual Wire Feed Assembly for Wider Weld Beads With Lower Heat Input
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Solution Overview
Problem
Existing welding techniques face challenges in increasing the width or length of the weld bead without simultaneously increasing the electrode diameter, which results in higher energy consumption and undesirable weld bead profiles.
Innovation Solution
A dual wire configuration system where two wire electrodes of different diameters are driven simultaneously through a circumferential groove and a contact tip assembly, with a sensor system to monitor wire consumption and a controller to manage the current waveform, forming a bridge droplet before deposition to achieve the desired weld profile with reduced heat input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the diameter of the electrode is increased to increase the weld bead width or length, then the weld bead width and length are improved, but the energy consumption and heat input increase excessively
Solution Approach 1:
The patent divides a single large electrode into multiple smaller electrodes (typically two or more wires). Each smaller electrode contributes to the overall weld bead formation, achieving the desired weld bead width and length without requiring a single large electrode that would consume excessive energy. The segmented electrodes are fed through a circumferential groove and contact tip assembly to work simultaneously.
Solution Approach 2:
The patent combines multiple smaller electrodes into a unified welding system where they operate simultaneously to achieve the cumulative effect of a larger electrode. By merging the deposition from multiple electrodes, the system achieves increased weld bead width and length while maintaining lower energy consumption per electrode, thus resolving the contradiction between weld bead size and energy efficiency.
2Length of stationary object
If the diameter of the electrode is increased to increase the weld bead width or length, then the weld bead width and length are improved, but the heat input into the weld increases
Solution Approach 1:
The patent segments the welding function across multiple smaller electrodes, allowing each electrode to contribute to elongating the weld puddle without requiring excessive heat input from a single large electrode. The distributed heat input from multiple smaller electrodes achieves the desired puddle length more efficiently.
Solution Approach 2:
The patent employs a bridge droplet formation mechanism where droplets from multiple electrodes merge before contacting the weld puddle. This preliminary merging action allows for better control of heat distribution and puddle elongation, achieving the desired weld puddle length while managing heat input more effectively than a single large electrode would provide.
3Productivity
If the diameter of the electrode is increased to increase the wire deposition rate, then the deposition rate is improved, but the energy consumption increases
Solution Approach 1:
The patent combines the deposition output from multiple smaller electrodes to achieve a cumulative deposition rate that rivals or exceeds that of a single large electrode. By merging the material contribution from multiple electrodes, the system achieves high productivity while maintaining lower energy consumption per electrode, resolving the contradiction between deposition rate and energy efficiency.
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 approach allows for increased weld bead width or length without excessive energy consumption, improving mechanical applications and deposition rates while maintaining stable arc performance and reduced heat input.
Implementation Method 1
The contact tip assembly is configured to deliver the current waveform to both of the first wire electrode and the second wire electrode. The distance S is configured to facilitate formation of a bridge droplet between the first wire electrode and the second wire electrode by the current waveform
Data Source
AI summary
A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.