Integrated Hybrid Welding Power Source Synchronizing Arc and Laser Outputs
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Solution Overview
Problem
Conventional hybrid welding systems lack effective coordination between arc welders and laser welders, leading to suboptimal heat input control and weld quality, as their control mechanisms operate separately and do not leverage real-time feedback and status information for synergistic control.
Innovation Solution
An integrated hybrid welding power source that coordinates the outputs of an arc welding power supply and a laser power supply in real time using a common clock signal or state-based system, allowing for simultaneous monitoring and modification of welding feedback and status information to optimize both arc and laser outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate control mechanisms are used for arc welder and laser welder, then device complexity is reduced and ease of operation is improved, but manufacturing precision and heat input control deteriorate
Solution Approach 1:
The patent merges the control of arc welder and laser welder into a unified control system that coordinates both welding processes. The system integrates multiple power supplies and control circuits to manage arc and laser outputs simultaneously, enabling synchronized operation and real-time parameter adjustment based on feedback from both welding processes, thereby achieving precise heat input control and weld quality improvement
2Device complexity
If separate control mechanisms are used for arc welder and laser welder, then device complexity is reduced, but manufacturing precision and weld quality deteriorate
Solution Approach 1:
The control systems of the arc welder and laser welder are merged into an integrated hybrid welding system with unified control architecture. The system combines multiple power supplies, control circuits, and feedback mechanisms into a coordinated whole that manages both welding processes simultaneously, enabling real-time parameter adjustment and precise heat input control
3Manufacturing precision
If real-time coordination is implemented between arc welder and laser welder, then manufacturing precision and heat input control are improved, but device complexity increases
Solution Approach 1:
The system implements feedback control by monitoring welding parameters from both arc and laser processes and using this information to dynamically adjust power supply outputs. Sensors detect welding conditions and feed this data back to the control system, which automatically modifies welding parameters to maintain optimal heat input and weld quality
Solution Approach 2:
Multiple power supplies and control circuits are merged into an integrated system with coordinated control architecture. The unified control system manages arc and laser power supplies simultaneously, enabling real-time parameter adjustment and synchronized operation through integrated control circuits that coordinate both welding processes
4Reliability
If real-time feedback coordination is implemented, then weld quality and heat input control are improved, but device complexity and control system complexity increase
Solution Approach 1:
The control system continuously monitors welding parameters from both arc and laser processes through integrated sensors and feedback circuits. This feedback information is used to dynamically adjust power supply outputs in real-time, ensuring consistent weld quality and proper heat input control throughout the welding process
Data Source
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AI summary
A system and method for controlling a hybrid welding process. An integrated hybrid welding power source (100) includes a first power supply (200) for providing a first welding output and a second power supply (300) for providing a second welding output. The first power supply (200) and the second power supply (300) are operatively connected to coordinate the first welding output with the second welding output in real time while operating concurrently.