Closed-Loop MIG Welding With Current Recess to Reduce Spatter
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Solution Overview
Problem
Existing welding systems, particularly those using MIG techniques, face issues such as limited travel speed, excessive spatter, and suboptimal penetration due to energy imbalances during short circuit processes, which affect weld quality and system performance.
Innovation Solution
A welding system with power circuitry and control circuitry that implements closed-loop voltage control, detects a predetermined rate of change in welding parameters, suspends voltage control to create a current recess, and resumes voltage control, thereby reducing energy input and improving weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If short circuit welding processes are used, then weld penetration is improved, but excessive spatter is generated and energy input becomes uncontrolled
Solution Approach 1:
The patent applies periodic pulsed current instead of continuous current, creating cycles of current application and interruption. This pulsed action allows the arc to be established and maintain penetration while periodically reducing energy input to minimize spatter generation during short circuit events.
Solution Approach 2:
The patent dynamically changes current parameters by implementing a control regime that suspends closed-loop voltage control and applies current recesses when short circuits are detected. This parameter modification allows optimization of penetration during arc phases while reducing energy during short circuit phases.
2Stability of the object's composition
If continuous voltage control is maintained during short circuits, then weld pool stability is improved, but excessive energy is added to the weld
Solution Approach 1:
The patent employs feedback control by monitoring welding parameters and detecting when short circuits occur. Based on this feedback, the system automatically suspends closed-loop voltage control and applies current recesses, creating a responsive control mechanism that adapts energy input to actual welding conditions.
Solution Approach 2:
The patent prepares for energy reduction by having the control regime ready to suspend voltage control and apply current recesses immediately upon detection of short circuit conditions, preventing excessive energy accumulation before it occurs.
3Productivity
If spray mode welding is used, then deposition efficiency is improved, but the process runs excessively hot for particular applications
Solution Approach 1:
The patent uses periodic pulsed current with distinct on and off phases, allowing the weld pool to be heated during current application phases for efficient deposition while cooling during interruption phases, thereby controlling overall temperature levels.
Solution Approach 2:
The patent modifies current parameters through suspension of voltage control and application of current recesses, enabling dynamic adjustment of energy input to maintain deposition efficiency while preventing excessive temperature rise in temperature-sensitive applications.
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 weld quality by reducing spatter, allowing for faster travel speeds, and achieving a more controlled energy input, resulting in improved weld penetration and reduced spatter.
Implementation Method 1
power circuitry configured to convert incoming power from a source to welding power
Implementation Method 2
detection of a predetermined rate of change of a welding parameter
Implementation Method 3
an arc is established between the welding wire and a workpiece to be welded. Electrical power is applied to the welding wire and a circuit is completed through the workpiece to sustain the arc that melts the wire and the workpiece
Data Source
AI summary
A welding regime may implements cyclic short circuits under a closed loop voltage control approach. Upon clearing or imminent clearing of the short circuit, a current recess is implemented. The current recess reduces the current that would otherwise be applied to the weld, resulting in multiple benefits. The recess may be implemented by suspending voltage command signals. Following the current recess, normal control is resumed with the then-current voltage command.