Electroslag Strip Cladding Stop Sequence for Trailing Strip Retraction
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Solution Overview
Problem
Electroslag strip cladding processes face challenges in efficiently stopping operations with multiple strips, leading to potential weld integrity issues and additional work due to trailing strips becoming stuck in the molten slag pool, which requires costly cutting and re-welding operations.
Innovation Solution
A method and system that detect the initiation of a stop phase during electroslag welding, stop the feeding of the first strip, and reverse the feed direction of the second strip to retract it from the molten slag pool, ensuring proper removal and preventing sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple strips are fed into the same molten slag pool to increase productivity and deposition rate, then the deposition rate and productivity are improved, but the trailing strip may become stuck in the solidifying slag pool when operations are stopped, requiring additional cutting and re-welding operations
Solution Approach 1:
The system performs preliminary action by detecting the initiation of a stop phase and stopping the feed of trailing strips before the molten slag pool solidifies. This prevents the trailing strip from becoming stuck in the solidifying slag, eliminating the need for additional cutting and re-welding operations while maintaining weld integrity
Solution Approach 2:
The system uses feedback by detecting the stop phase initiation and automatically adjusting the strip feed mechanism to stop feeding trailing strips. This closed-loop control ensures the trailing strip is removed from the molten slag pool at the appropriate time, preventing sticking issues while maintaining high productivity during normal operation
2Reliability
If the feed direction of the trailing strip is reversed to retract it from the molten slag pool, then the weld integrity is improved by preventing sticking, but the device complexity increases due to the need for bidirectional feed control
Solution Approach 1:
The system applies dynamics by making the strip feed mechanism reversible, allowing it to change direction based on operational phase. The feed mechanism can operate in forward direction during normal cladding and reverse direction during stop phase to retract trailing strips, providing adaptive control without requiring separate mechanisms for each function
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 improves weld quality by preventing trailing strips from becoming stuck in the solidified slag, reducing the need for additional operations and minimizing material and time costs, while maintaining high-quality welds without the need for further finishing.
Implementation Method 1
electroslag welding operation feeding a first strip and a second strip towards a molten slag pool... based on the ohmic resistance heating of an electrically conductive slag to create a pool of molten slag
Data Source
AI summary
Stopping electroslag strip cladding operations feeding multiple strips includes detecting, during a welding phase of an electroslag welding operation feeding a first strip and a second strip towards a molten slag pool formed on a work piece, initiation of a stop phase. Upon detection the feeding of the first strip towards the molten slag pool is stopped. Additionally, a feed direction of the feeding of the second strip is reversed to retract the second strip away from the molten slag pool.