MIG/MAG Welding Control Using Short-Circuit Time Feedback
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Solution Overview
Problem
Existing MIG/MAG-welding technologies face challenges in achieving consistent weld results due to variations in electrode material, dimensions, shielding gas compositions, and distance between the contact tip and workpiece, leading to uncertainty and instability in the welding process, especially at different supplier batches and varying welding conditions.
Innovation Solution
A regulator is introduced to maintain a constant short-circuiting time percentage, which stabilizes the welding process by adjusting the current source's static and dynamic characteristics, allowing for tolerance to external factors and reducing the need for pre-tested synergy lines, and can be implemented in both advanced and simple welding machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional MIG/MAG-welding control methods are used, then the welding process can operate with simple equipment, but the weld results are inconsistent due to variations in electrode material, dimensions, shielding gas compositions, and distance between contact tip and workpiece
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the welding voltage and compares it to a reference value. The controller adjusts the electrode feed speed based on the voltage deviation to maintain consistent welding conditions. This closed-loop feedback mechanism compensates for variations in electrode material, dimensions, shielding gas composition, and contact tip distance, ensuring reliable and consistent weld results across different operating conditions and supplier batches.
2Ease of operation
If the distance between contact tip and workpiece varies, then the welding process becomes more flexible and easier to operate, but the weld quality becomes unstable and unpredictable
Solution Approach 1:
The feedback control system continuously monitors welding voltage, which naturally varies with changes in contact tip to workpiece distance. When the distance increases, voltage rises; when distance decreases, voltage drops. The controller detects these voltage changes and automatically adjusts the electrode feed speed to compensate, maintaining stable weld quality regardless of positioning variations and reducing the need for precise manual positioning.
Solution Approach 2:
The system dynamically adjusts the electrode feed speed in real-time based on instantaneous voltage conditions rather than using a fixed feed rate. This dynamic adaptation allows the welding process to automatically compensate for changing distances between contact tip and workpiece, maintaining manufacturing precision while preserving operational flexibility.
3Adaptability or versatility
If different supplier batches of electrodes or shielding gases are used, then the welding process can adapt to available materials, but the weld results become uncertain and require extensive re-testing
Solution Approach 1:
The feedback control system continuously monitors welding voltage, which reflects the actual welding conditions including electrode characteristics and shielding gas properties. By comparing the measured voltage to the reference value and automatically adjusting the electrode feed speed, the system compensates for variations between different supplier batches and material specifications. This ensures predictable and reliable weld results without requiring extensive re-testing when changing materials.
4Reliability
If the current source has fixed static characteristics, then the equipment is simpler and more reliable, but the welding process cannot adapt to varying conditions and loses stability
Solution Approach 1:
The patent transforms the fixed static current source into a dynamic control system that continuously adjusts the electrode feed speed based on real-time voltage feedback. The controller modifies the feed speed to maintain the voltage at the reference value, adapting to varying welding conditions while preserving the simplicity and reliability of the basic equipment architecture. This dynamic adaptation provides process stability without requiring complex modifications to the current source itself.
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 solution enhances the stability and accuracy of the welding process across different electrode dimensions, materials, and shielding gas compositions, ensuring consistent results and reducing the need for extensive testing, while also being usable in the spray area with minimal spatter and heat transfer.
Implementation Method 1
the workpiece is heated primarily by the arc
Implementation Method 2
the material transport from the electrode to the workpiece takes place through large short-circuiting droplets
Data Source
AI summary
The present invention refers to a control method and welding equipment for MIG/MAG-welding with presence of short-circuiting droplets between an electrode end and a workpiece. The method comprises establishment of a short-circuiting time, establishment of an arc time, and controlling the energy supplied to the electrode. The energy supply is controlled in such a way that the energy supply is increased if a measured short-circuiting time of a total period time, where the period time is the sum of the short-circuiting time and the arc time, exceeds a defined adjustable set value and decreases if said short-circuiting percentage goes below said set value.