Fillet Welding Torch Weaving Path for One-Pass Root Penetration
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Solution Overview
Problem
Existing fillet welding techniques face challenges in achieving efficient one-pass welding with a single electrode, particularly in maintaining leg length and preventing weld defects like lack of penetration, undercut, and overlap, especially in automated processes and various welding postures such as downward and vertical fillet welding.
Innovation Solution
A weaving control method that uses a single electrode to perform fillet welding by setting a welding torch position with a weaving reference line passing through a base point on the weld line, with at least five fixed end points on both sides, and moving the torch along a polygon trajectory, adjusting distances, speeds, and welding conditions to ensure proper penetration and bead appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single electrode is used for one-pass welding, then welding efficiency is improved, but penetration of the root portion becomes insufficient and weld defects occur
Solution Approach 1:
The patent applies dynamic weaving motion to the welding torch, moving it in a predetermined pattern (such as sinusoidal or triangular waveform) during the welding process. This dynamic movement allows the single electrode to distribute heat more effectively across the weld joint, ensuring sufficient penetration of the root portion while maintaining high welding efficiency through one-pass welding.
Solution Approach 2:
The welding torch performs periodic weaving motion at specific frequencies and amplitudes during welding. This periodic action creates alternating zones of heat concentration and distribution, allowing the molten pool to properly penetrate the root portion while preventing weld defects such as undercut and overlap, thus resolving the contradiction between efficiency and penetration quality.
2Manufacturing precision
If weaving operation is performed with fixed end points on both sides of the weaving reference line, then penetration and bead appearance are improved, but device complexity increases
Solution Approach 1:
The patent establishes specific parameter ranges for the weaving operation, including setting fixed end points at predetermined distances from the weaving reference line (e.g., 3-10 mm), controlling weaving amplitude and frequency within specific ranges, and adjusting welding speed accordingly. These parameter changes enable automated control systems to achieve consistent weld quality without requiring complex manual intervention, thus improving weld quality while managing device complexity through standardized parameters.
3Productivity
If torch angle and target position are optimized for large leg length, then welding efficiency is improved, but penetration of root portion becomes difficult
Solution Approach 1:
The patent segments the welding process into distinct phases: an initial phase where the torch is positioned to ensure root portion penetration with appropriate angle and distance, followed by a weaving phase that maintains leg length while distributing heat. This segmentation allows optimization of torch angle and target position for penetration reliability in the critical initial phase, while maintaining welding efficiency through automated weaving in subsequent phases.
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 method enables efficient one-pass welding with a single electrode, preventing weld defects and maintaining good bead appearance and weldability, while allowing for automation and application in various welding postures.
Implementation Method 1
Gas shielded arc welding is generally applied as the fillet welding
Data Source
AI summary
A weaving control method in fillet welding. On a surface perpendicular to a welding direction, a position of the welding torch is set such that a weaving reference line passes through a base point on a weld line, and at least five fixed end points are set, and positions of the fixed end points are set such that one or more of the fixed end points are provided on each of both sides across the weaving reference line and a reference end point a being on the weaving reference line and having the shortest distance between a tip and a base metal is provided. The weaving operation is performed such that the welding torch moves between the fixed end points along with a trajectory forming a polygon when viewed from the welding direction.