Hybrid Induction Welding with Electrode Preheating for Faster Starts
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Solution Overview
Problem
Current welding techniques lack a method to ensure the electrode is heated prior to the initiation of the welding operation, affecting initial welding performance and productivity.
Innovation Solution
A hybrid induction welding system that combines inductive heating of the workpiece with resistive preheating of the electrode wire, using an induction heating coil to preheat the workpiece and a preheating power supply to heat the electrode wire before the welding arc is initiated, allowing for a controlled and balanced heat profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional welding techniques are used without preheating the electrode, then the welding system is simple and easy to operate, but the initial welding performance is inconsistent and productivity is reduced
Solution Approach 1:
The patent applies preliminary action by preheating the electrode wire before welding using resistive heating through a contact tip, and preheating the workpiece using induction heating. This preliminary heating action ensures consistent initial welding performance and enables higher welding speeds without compromising system simplicity
Solution Approach 2:
The patent introduces an intermediary heating system that includes a preheating power supply, contact tip, and induction heating device. This intermediary system mediates between the power source and the welding arc, providing controlled preheating of both electrode and workpiece to improve productivity while maintaining operational simplicity
2Use of energy by moving object
If the welding arc is initiated with a cold electrode, then the system requires less additional heating equipment, but more energy is required from the welding arc and welding speed is limited
Solution Approach 1:
The system performs preliminary heating of the electrode wire through resistive heating in the contact tip and preliminary heating of the workpiece through induction heating. This reduces the energy burden on the welding arc itself, allowing more energy to be used for melting and welding rather than heating, thereby increasing welding speed
Solution Approach 2:
The patent changes the temperature parameter of the electrode and workpiece before welding begins. By controlling the preheating temperature through separate power supplies, the system optimizes the energy distribution between preheating and welding operations, enabling higher welding speeds with efficient energy utilization
3Productivity
If rapid welding is performed without preheating, then productivity increases, but distortion and stress in the workpiece increase
Solution Approach 1:
The system performs preliminary induction heating of the workpiece area to be welded, creating a controlled heat-affected zone. This preliminary heating reduces thermal gradients during rapid welding, minimizing distortion and stress while maintaining high welding speeds
Solution Approach 2:
The induction heating device applies localized preheating to specific areas of the workpiece using a coil positioned near the weld zone. This creates a controlled thermal profile with different temperature zones, reducing overall distortion while enabling rapid welding in the heated area
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 enhances welding efficiency by reducing the energy required for the welding arc, enabling higher welding speeds and improved productivity, while minimizing distortion and stress in the workpieces by achieving a uniform heat distribution.
Implementation Method 1
an induction heating coil to preheat the workpiece
Implementation Method 2
inductively heating a workpiece
Implementation Method 3
resistive preheating of the electrode wire
Data Source
AI summary
Systems, methods, and apparatus to weld by preheating welding wire and inductively heating a workpiece are disclosed. An example welding system includes: a welding current source configured to provide welding current to a welding circuit, the welding circuit comprising an electrode wire and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the electrode wire via a second contact tip of the welding torch; and at least one induction heating coil configured to apply induction heat to a workpiece, the welding current source, the electrode preheating circuit, and the induction heating coil configured to perform a preheating operation and a welding operation on the workpiece.