Force-Controlled Hot Wire Feed Start to Prevent Welding Arcing
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Solution Overview
Problem
Current hot wire welding and cladding machines rely on voltage and current feedback to control the resistive heating process, which can lead to arcing issues due to varying wire types, causing inconsistencies and base metal melting, and require specific parameter settings for each wire type.
Innovation Solution
Employing force feedback from the wire to control the metalworking operation, using a signal indicative of the force on the wire to detect initial contact with the workpiece and adjust the heating process to prevent arcing, allowing for a controlled start and stable wire feeding by resuming feeding based on force feedback rather than or in addition to voltage and current feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If voltage and current feedback are used to control the resistive heating process, then the wire can be heated to sufficient temperature, but arcing occurs due to electromagnetic pinch forces
Solution Approach 1:
The patent employs force feedback from the wire to control the metalworking operation. A signal indicative of force on the wire is used to detect initial contact with the workpiece and adjust the heating process. This feedback mechanism allows the system to respond to actual wire conditions rather than relying solely on voltage and current measurements, preventing arcing by maintaining appropriate force levels during the heating process.
Solution Approach 2:
The patent changes the control parameter from voltage/current feedback to force feedback. By monitoring force on the wire rather than electrical parameters, the system can detect wire contact with the workpiece and adjust heating accordingly. This parameter change eliminates the need for specific wire type settings and prevents arcing across different wire types.
2Reliability
If specific parameter settings are used for each wire type, then consistent heating can be achieved, but the device complexity increases and requires multiple programs
Solution Approach 1:
The patent makes the control system universal by using force feedback instead of wire-type-specific electrical parameters. The force feedback mechanism works across different wire types without requiring separate programs or parameter settings. This single control approach handles multiple wire types uniformly, eliminating the need for complex configuration while maintaining consistent heating performance.
Solution Approach 2:
The system uses the wire's own force signal during feeding as the control parameter. The wire essentially controls its own heating process by providing force feedback that indicates its contact state with the workpiece. This self-service approach eliminates the need for external parameter programming and adapts automatically to different wire types.
3Stability of the object's composition
If the wire is heated to high temperature to achieve plastic deformation, then the wire can be properly fed, but electromagnetic pinch forces cause arcing
Solution Approach 1:
The patent uses force feedback to monitor the wire during heating and feeding. By detecting the force signal indicative of wire contact with the workpiece, the system can adjust heating to achieve plastic deformation without excessive temperature that would generate harmful electromagnetic pinch forces and arcing.
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 eliminates the need for specific wire parameter settings and reduces arcing, ensuring consistent weld quality across different wire types by using force feedback to maintain the wire in a softened state, thereby preventing electromagnetic pinch forces from causing arcs.
Implementation Method 1
a metal filler wire is resistively heated, typically, to a softened or plastic or semi-liquidus state, usually by passing an electrical current through it
Implementation Method 2
Employing force feedback from the wire to control the metalworking operation, using a signal indicative of the force on the wire
Data Source
AI summary
A method for controlling a start of a metalworking operation. The method includes detecting an initial contact between a wire being fed from a welding apparatus and a workpiece and, in response to the detection, halting feeding of the wire from the welding apparatus. The method further includes activating a high energy heat source configured to heat a tip of the wire and resuming the feeding of the wire from the welding apparatus when the tip of the wire is heated by the high energy heat source to a plastic state. The feeding of the wire is resumed by measuring a force feedback from the wire contacting the workpiece. An apparatus for implementing the method is also disclosed.