Filler Wire and Heat Source Motion Control for Weld Puddle Shaping
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Solution Overview
Problem
Traditional filler wire welding methods face challenges in achieving high deposition rates and precise weld profiles due to issues like wire feed slippage, arc formation, and difficulty in controlling the cooling rate of the weld puddle, leading to substandard weld quality and increased spatter.
Innovation Solution
A system and method that control the movement of a filler wire and a high energy heat source, such as a laser or arc welding device, to create a molten puddle and deposit the filler wire in a controlled manner, allowing for precise adjustment of weld shape, profile, and cooling rate, using a combination of motors and sensors to synchronize the movement of the wire and heat source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional arc welding with filler wire is used to increase deposition rates, then welding speed improves, but wire feed slippage and arc formation cause loss of reliability
Solution Approach 1:
The patent replaces the traditional mechanical wire feed system with a robotic arm that uses controlled motion to deliver filler material. The robotic arm positions a filler container near the weld zone and uses controlled dispensing rather than mechanical feeding through contact tubes, eliminating slippage and arc formation issues associated with traditional wire feed mechanisms.
Solution Approach 2:
The patent introduces a robotic arm as an intermediary between the filler material storage and the weld zone. This intermediary system controls the delivery and positioning of filler material without direct mechanical contact with the arc or molten puddle, preventing the harmful effects of wire feed slippage and unintended arc formation that occur in traditional systems.
2Productivity
If traditional filler wire method is used to achieve high deposition rates, then productivity improves, but manufacturing precision of weld profile deteriorates
Solution Approach 1:
The patent employs a dynamic robotic arm system that can adjust its position, orientation, and filler dispensing rate in real-time based on weld pool conditions and desired profile requirements. This dynamic control enables precise manipulation of filler material delivery, allowing optimization of both deposition rate and weld profile geometry that static traditional systems cannot achieve.
Solution Approach 2:
The patent implements a feedback control system that monitors weld pool characteristics and adjusts robotic arm positioning and filler dispensing accordingly. Sensors detect weld pool temperature, size, and shape, and this information feeds back to the control system which modifies filler delivery parameters to achieve the desired weld profile while maintaining high deposition rates.
3Productivity
If high energy heat source is used to create molten puddle for fast welding, then productivity improves, but heat input causes increased distortion
Solution Approach 1:
The patent segments the heating process by using a focused high-energy heat source that concentrates thermal energy precisely on the weld zone while minimizing heat input to surrounding areas. This segmentation of thermal energy delivery allows fast welding speeds without excessive heat input that would cause distortion, as the heat is localized only where needed for molten puddle formation.
Solution Approach 2:
The patent applies local quality by directing high-energy heat input only to the specific weld zone where molten puddle formation is required, while keeping surrounding areas at lower temperatures. This localized heating approach enables high welding speeds in the weld zone without causing thermal distortion in the broader workpiece structure.
4Device complexity
If traditional arc welding is used without shielding, then device complexity reduces, but harmful factors from air exposure increase
Solution Approach 1:
The patent replaces traditional mechanical shielding systems (gas delivery apparatus, contact tubes) with a robotic arm-based filler delivery system. This substitution eliminates the need for complex shielding gas delivery mechanisms while the robotic arm's precise positioning and controlled filler dispensing minimize exposure to air contamination, achieving protection with reduced complexity.
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 enables faster welding with reduced spatter, precise weld profiles, and low distortion, allowing for high-speed welding of complex materials and adverse environments without shielding, while maintaining high deposition rates and quality.
Implementation Method 1
heating at least one workpiece with a high energy heat source to create a molten puddle
Implementation Method 2
The wire is fed through a contact tube toward a workpiece and extends beyond the tube. The extension is resistance-heated such that the extension approaches or reaches the melting point
Data Source
AI summary
A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.