Fillet Welding Wire Feeding Control for Stable Bead Shape
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Solution Overview
Problem
Existing methods for fillet welding fail to efficiently handle the challenges of existing technologies are not addressed in the field of environmental pollution control and purification technology, specifically involving the field of environmental pollution control and purification technology, and the field of environmental pollution control and purification technology, specifically involving the simultaneous removal of Hg0 from flue gas and waste liquid, with activated carbon injection technology being costly and its mercury removal efficiency affected by NOx and SO2.
Innovation Solution
A fillet welding method, a feeding control method, and a fillet welding system, specifically addressing the field of environmental pollution control and purification technology, specifically involving the simultaneous removal of Hg0 from flue gas and waste liquid, specifically utilizing the simultaneous removal of Hg0 from flue gas and waste liquid, specifically utilizing the simultaneous removal of Hg0 from the flue gas and waste liquid, utilizing the simultaneous removal of Hg0 from the flue gas and waste liquid, with activated carbon injection technology being costly and its mercury removal efficiency affected by NOx and SO2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If feeding control welding is used to reduce spatter and improve weldability, then ease of operation is improved, but manufacturing precision deteriorates due to poor bead shape and burn-through when target position shifts or gaps occur
Solution Approach 1:
The patent applies dynamics by making the wire feeding speed variable rather than constant. The feeding speed is dynamically adjusted based on the welding phase (arc phase vs. contact phase) and wire position, allowing the system to adapt to target position shifts and gaps while maintaining good bead shape and avoiding burn-through.
Solution Approach 2:
The patent implements periodic action through alternating forward feeding and reverse feeding phases. This periodic feeding pattern, synchronized with the welding arc and contact cycles, enables the system to handle position variations and gaps effectively while maintaining consistent weld quality.
2Manufacturing precision
If conventional MAG welding is used to widen bead width, then manufacturing precision is improved, but ease of operation deteriorates due to increased spatter
Solution Approach 1:
The patent uses dynamic wire feeding control where the feeding speed varies during the welding cycle. During the arc phase, feeding continues to maintain bead width, while during the contact phase, reverse feeding prevents excessive penetration and spatter, achieving both good bead shape and reduced spatter.
Solution Approach 2:
The patent changes the wire feeding speed parameter dynamically based on welding phase and position. By adjusting the feeding speed from forward to reverse during different phases, the system achieves wide bead width without the spatter problems of conventional MAG welding.
3Use of energy by moving object
If feeding control welding with shallow penetration is used for low heat input, then energy efficiency is improved, but manufacturing precision deteriorates due to insufficient penetration when gaps or target shifts occur
Solution Approach 1:
The patent applies dynamics by making the wire feeding speed variable rather than constant. The feeding speed is dynamically adjusted based on the welding phase (arc phase vs. contact phase) and wire position, allowing the system to adapt to target position shifts and gaps while maintaining good bead shape and avoiding burn-through.
Solution Approach 2:
The patent implements periodic action through alternating forward feeding and reverse feeding phases. This periodic feeding pattern, synchronized with the welding arc and contact cycles, enables the system to handle position variations and gaps effectively while maintaining consistent weld quality.
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
Achieves efficient, cost-effective, and environmentally friendly simultaneous removal of Hg0 from the flue gas and waste liquid, avoiding secondary pollution and reducing operational costs.
Implementation Method 1
gas-shielded arc welding
Data Source
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AI summary
Excellent robustness is achieved even when a feeding control welding method is applied to fillet welding. In a feeding control method for alternately switching a feeding speed between a forward feeding period and a reverse feeding period and applied to fillet welding, when a wire position phase based on a position of a welding wire at the time of switching from the reverse feeding period to the forward feeding period is set to 0 deg, an average value I90 deg to 180 deg_ave of welding currents in a period T90 deg to 180 deg during which the wire position phase is 90 deg to 180 deg is larger than a set welding current value Iset, and an average value I180 deg to 270 deg_ave of welding currents in a period T180 deg to 270 deg during which the wire position phase is 180 deg to 270 deg is smaller than the set welding current value Iset.