Interconnected Welding Wire Coil for Seamless Multi-Material Transitions
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Solution Overview
Problem
Existing welding methods require interruptions to change welding wires and parameters based on workpiece geometry, compromising welding quality and increasing complexity.
Innovation Solution
A method and device that pre-assemble interconnected welding wires of varying lengths and materials on a wire coil, allowing seamless transitions and automatic parameter adjustments during the welding process, ensuring uninterrupted welding with high quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If welding wire is changed during the welding process to match different workpiece geometries, then welding quality is improved, but welding process continuity is interrupted and complexity increases
Solution Approach 1:
The welding wire is divided into multiple segments with different materials and properties, each optimized for specific workpiece geometries. The wire coil contains sequentially arranged welding wire segments that automatically engage based on the workpiece region being welded, eliminating the need to stop and change entire wire spools.
Solution Approach 2:
Different welding wire segments are pre-assembled in the wire coil according to the expected welding sequence. The wire feed system is prepared with multiple wire segments before welding begins, allowing automatic transition between wire types as the welding progresses through different workpiece regions.
2Reliability
If multiple welding devices are used to maintain continuous welding with different wires, then welding quality is maintained, but system complexity and cost increase
Solution Approach 1:
A single welding device is designed to perform multiple functions by accommodating different welding wire segments within one wire coil. The wire feed system can handle various wire types, diameters, and materials through a unified mechanism, replacing the need for multiple specialized welding devices.
Solution Approach 2:
Multiple welding wire functions are merged into a single continuous wire feed system. The patent combines different welding wire segments into one coil that feeds through a single device, integrating what would traditionally require separate devices into one unified system.
3Manufacturing precision
If welding wire is changed to match different workpiece regions, then optimal welding parameters are achieved, but welding process time increases due to interruptions
Solution Approach 1:
The welding process maintains continuous motion without interruptions by pre-arranging different wire segments in the coil. As the welding torch moves along the workpiece, the corresponding wire segment is automatically fed, ensuring the useful welding action continues uninterrupted with optimal parameters for each region.
Solution Approach 2:
The optimal welding wire segments are preliminarily arranged in the correct sequence within the wire coil before welding begins. This pre-positioning allows the welding process to automatically use the correct wire type for each workpiece region without stopping to select or change wires.
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
Enables high-quality, uninterrupted welding processes across different workpiece materials and geometries with reduced operational complexity and costs, maintaining optimal welding parameters through accurate detection and feedback mechanisms.
Implementation Method 1
a melting welding wire, which is supplied to the welding torch
Implementation Method 2
Method for performing a welding process on a workpiece by a welding torch
Data Source
AI summary
A method and a welding device for performing a welding process on a workpiece by a welding torch, uses a melting welding wire, which is arranged on a wire coil and may be supplied to the welding torch via a hose package, wherein different welding wires and different welding parameters are used depending on the geometry of the workpiece. A welding wire formed by the different interconnected welding wires in lengths depending on the geometry of the workpiece is arranged on the wire coil, so the welding process may be performed without interruptions using the different welding wires and the different welding parameters by supplying to the welding torch the welding wire formed by the different interconnected welding wires from the wire coil.