Dynamic Welding Current Variation for Container Seam Quality
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Solution Overview
Problem
Current methods for determining the optimal welding current strength for resistance seam welding of container bodies are time-consuming and material-intensive, relying on iterative test weldings with alternating current, which can result in either inadequate adhesion or spatter, making it difficult to set the current strength accurately.
Innovation Solution
A method and apparatus that vary the welding current strength along the seam of a test body, allowing for determination of the appropriate current strength by creating a region between adhesion and spatter, and storing this information for use in serial production, enabling a more precise and efficient setting of the welding current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iterative test weldings with constant current strength are performed to determine optimal welding parameters, then welding quality can be achieved, but time consumption and material consumption increase significantly
Solution Approach 1:
The patent applies dynamics by transitioning from constant current strength to dynamically varying current strength during welding. The welding current is varied according to a predetermined pattern (increasing, decreasing, or oscillating) to create different welding conditions along the seam, allowing identification of optimal current strength without multiple test weldings.
Solution Approach 2:
The patent changes the welding current strength parameter during the welding process. By systematically varying the current strength along the seam length or during the welding cycle, the method creates a spectrum of welding conditions in a single test welding, enabling determination of optimal parameters while minimizing time and material consumption.
2Manufacturing precision
If iterative test weldings with constant current strength are performed to determine optimal welding parameters, then welding quality can be achieved, but material consumption increases due to creation of multiple test bodies
Solution Approach 1:
The patent applies dynamics by transitioning from constant current strength to dynamically varying current strength during welding. The welding current is varied according to a predetermined pattern (increasing, decreasing, or oscillating) to create different welding conditions along the seam, allowing identification of optimal current strength without multiple test weldings.
Solution Approach 2:
The patent changes the welding current strength parameter during the welding process. By systematically varying the current strength along the seam length or during the welding cycle, the method creates a spectrum of welding conditions in a single test welding, enabling determination of optimal parameters while minimizing time and material consumption.
3Strength
If high welding current strength is used to ensure adequate material melting and adhesion, then welding strength improves, but spatter and craters occur reducing body usability
Solution Approach 1:
The patent applies local quality by creating different current strength conditions at different locations along the welding seam. By varying the current strength along the seam length, the method identifies the specific current strength value that achieves adequate adhesion without causing spatter or craters, applying the right amount of energy locally rather than uniformly throughout the entire seam.
Solution Approach 2:
The patent changes the welding current strength parameter during the welding process. By systematically varying the current strength along the seam length or during the welding cycle, the method creates a spectrum of welding conditions in a single test welding, enabling determination of optimal parameters while minimizing time and material consumption.
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 reduces the time and material required for determining the optimal welding current strength, allowing for better seam quality and reduced spatter, enabling efficient production with minimal test bodies and less material consumption.
Implementation Method 1
resistance seam welding of container bodies sequentially following one another
Implementation Method 2
welding rolls, a welding current generator and a welding current control
Data Source
AI summary
For the determination of the welding current to be used for the resistance welding of the overlap seam of container bodies, welding with a test body is carried out with a changing strength of welding current which in the test body produces a varying welding of the seam. The current strength varies from welding of this seam with a too high temperature to welding with a too low temperature. Along with this the welding current strength used in the welding is determined so that it is further determined at which point of the seam the welding has been accomplished and with what strength of welding current. By means of a mechanical and/or optical investigation of the welded seam it can then be easily determined where the seam has been correctly welded for the series production of container bodies from the same sheet material as the test bodies. When such a point or such a region of the seam is known the welding current used in the test welding can be taken as the welding current for serial production.