Flat Position Welding Condition Generation Method

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Solution Overview

Problem

Less experienced operators face difficulties in generating and determining optimal welding conditions for flat position welding, as existing techniques are not effective in providing appropriate settings for welding conditions in this specific context.

Innovation Solution

A method for determining welding conditions in flat position welding using two sets of parameters, Condition A and Condition B, which include geometrical parameters of the workpiece and welding specifications respectively, allowing for the combination and adjustment of parameters to generate optimal welding conditions, including welding current, speed, and weaving width, based on past records and learning from previous welding operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding conditions are determined manually by operators using existing techniques, then welding operations can be performed, but less experienced operators cannot generate and determine optimal welding conditions for flat position welding

Engineering Contradiction:

Improvequality of welding conditionsVSAvoiddifficulty for less experienced operators

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system automatically generates welding conditions by combining parameters from Condition A (geometrical parameters) and Condition B (welding specifications) without requiring manual intervention from operators. The control device performs automatic calculation and determination of optimal welding parameters, enabling the system to serve itself rather than relying on operator expertise.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical process of operator judgment and experience-based decision-making with an automated computational system. The control device uses algorithmic processing to combine geometric parameters and welding specifications, substituting human cognitive processes with mechanical computation to generate reliable welding conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If comprehensive welding conditions are manually set to ensure quality, then welding quality can be maintained, but the process becomes complex and time-consuming

Engineering Contradiction:

Improvewelding qualityVSAvoidcomplexity of welding condition setting

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides welding conditions into two distinct parameter sets: Condition A containing geometrical parameters (workpiece dimensions, groove shape, gap width) and Condition B containing welding specifications (welding method, material, position). This segmentation allows the complex setting process to be broken down into manageable components that are automatically combined by the control device.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system automatically adjusts and optimizes welding parameters by combining geometric parameters with welding specifications. The control device performs parameter transformation and calculation to determine optimal welding conditions, including welding current, voltage, speed, and other critical parameters, thereby managing complexity through automated parameter optimization.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If comprehensive welding conditions are manually set to ensure quality, then welding quality can be maintained, but the process becomes time-consuming

Engineering Contradiction:

Improvewelding qualityVSAvoidtime for setting welding conditions

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary automatic calculation and determination of welding conditions before the actual welding process begins. By pre-combining geometric parameters and welding specifications to generate optimal settings in advance, the system eliminates time-consuming manual adjustment during welding operations, thereby reducing overall preparation time while maintaining quality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces time-consuming manual processes of experiencing-based adjustment and trial-and-error with automated computational processing. The control device rapidly calculates optimal welding conditions by processing geometric parameters and specifications, substituting slow human decision-making with fast mechanical computation to reduce setup time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10744583B2Welding condition generating method in flat position welding

Publication Date: 2020.08.18 KOBE STEEL LTD

AI summary

A welding condition generating method in flat position welding is a method for determining welding conditions for welding in a single V groove, a single bevel groove, or a fillet groove in a flat position using a welding robot. The method includes preparing conditions A and B, each including a plurality of different parameters used in calculation for determining the welding conditions; and generating the welding conditions by combining parameters included in the conditions A and B. The condition A includes at least one of the following parameters: a joint shape, a groove shape, a groove angle, a gap width, and the presence or absence of backing. The condition B includes at least one of the following parameters: a welding gas type, a welding wire diameter, a welding wire type, a welding wire extension length, a welding source type, a power source characteristic, and a torch type.