Intermediate Wire Feeding for Stable High-Speed Arc Welding
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Solution Overview
Problem
Conventional arc welding systems face challenges in stably feeding welding wire at high speeds to achieve single pass welding of thick plates due to increased feeding load, which leads to issues like slippage and deformation, especially when the distance between the wire feeding source and the welding torch is long or when using a wire reel as the feeding source.
Innovation Solution
An arc welding system with an intermediate wire feeding source is introduced between the wire feeding source and the welding torch, which absorbs the feeding load and includes a detection unit and feed control unit to manage the welding wire supply, allowing stable feeding at high speeds by accommodating a predetermined amount of wire and reducing friction resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding wire is fed at high speed to achieve single pass welding of thick plates, then productivity is improved, but feeding load increases causing slippage and instability
Solution Approach 1:
An intermediate wire feeding source is introduced between the wire feeding source and the welding torch. This intermediate source acts as a mediator that absorbs the feeding load fluctuations, ensuring stable wire delivery to the welding torch at high speeds without slippage or instability.
2Adaptability or versatility
If the distance between wire feeding source and welding torch is increased, then adaptability is improved, but feeding load increases causing slippage
Solution Approach 1:
The intermediate wire feeding source serves as a mediator that decouples the relationship between the wire feeding source and welding torch. It absorbs the feeding load regardless of distance, allowing the system to adapt to various distances without experiencing slippage or feeding instability.
3Ease of operation
If wire reel is used as wire feeding source, then ease of operation is improved, but inertia increases causing feeding load and slippage
Solution Approach 1:
The intermediate wire feeding source acts as a mediator that isolates the welding torch from the inertia of the wire reel. It absorbs the feeding load variations caused by the reel's inertia, ensuring stable wire delivery while maintaining the ease of operation provided by the reel system.
4Manufacturing precision
If multi-layer welding is used for thick plates, then manufacturing precision is maintained, but the number of welding steps increases reducing productivity
Solution Approach 1:
The system changes the wire feeding speed parameter to high speed feeding (approximately 5 to 100 meters per minute) and increases current (300 A or more), enabling single pass welding of thick plates that previously required multi-layer welding, thus maintaining precision while improving productivity.
5Productivity
If feeding load is increased to achieve high speed wire feeding, then productivity is improved, but slippage between welding wire and roller occurs reducing reliability
Solution Approach 1:
The intermediate wire feeding source acts as a mediator that absorbs the high feeding load. It receives wire from the feeding source at high speed and delivers it steadily to the welding torch, preventing slippage between the wire and rollers while maintaining high productivity.
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 configuration enables stable single pass welding of thick plates by reducing the feeding load on the welding torch side, preventing slippage and deformation, and allowing for consistent wire feeding even with varying wire supply conditions.
Implementation Method 1
supplying electric power between the welding wire and a base material to generate arc which is used to weld the base material with its heat
Implementation Method 2
supplying electric power between the welding wire and a base material to generate arc
Data Source
AI summary
An arc welding system of a consumable electrode type comprises: a wire feeding device that feeds welding wire from a wire feeding source to a welding torch; and a power supply device that supplies electric power between the welding wire fed to the welding torch and a base material, the system being configured to weld the base material by arc generated by the supplied electric power. The wire feeding device is provided with: an intermediate wire feeding source that is disposed between the wire feeding source and the welding torch and is configured to temporarily accommodate the welding wire fed from the wire feeding source and to feed the accommodated welding wire to the welding torch; a pull-out feeding part that feeds the welding wire at the wire feeding source to the intermediate wire feeding source; and a push-out feeding part that feeds the welding wire accommodated in the intermediate wire feeding source to the welding torch.