MIG Welding Wire Sticking Prevention via Post-Stop Feeding
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Solution Overview
Problem
In gas shielded arc welding devices like MIG/MAG-welders, the wire electrode often sticks to the welding current tip after the welding arc is extinguished, causing issues with wire feeding and arc ignition, leading to impaired welding quality and potential damage to the tip.
Innovation Solution
A method involving a post-stop feeding step where the wire electrode is moved slightly relative to the welding current tip after the welding current is switched off and the wire feeding is stopped, with the welding current being gradually attenuated and wire feeding velocity decelerated, typically within 100-200 milliseconds after arc extinction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding current is switched off abruptly and wire feeding is stopped immediately after arc extinction, then the welding process terminates quickly, but the wire electrode sticks to the welding current tip causing feeding problems and arc ignition issues
Solution Approach 1:
The patent applies preliminary action by implementing a controlled current attenuation phase before complete shutdown. The welding current is gradually reduced to a low level (e.g., 1-10% of original current) over a predetermined time period (e.g., 10-100 milliseconds) after arc extinction, which prevents wire sticking to the tip while maintaining quick termination. This preliminary gradual reduction eliminates the harmful abrupt shutdown effect.
Solution Approach 2:
The patent applies dynamics by transitioning from static wire feeding to dynamic controlled feeding during termination. The wire feeding velocity is continuously adjusted during the attenuation phase, starting at normal feeding speed and gradually reducing to a lower speed or stopping. This dynamic adjustment ensures the wire is properly positioned and prevents sticking while maintaining productivity.
2Productivity
If the wire feeding is stopped immediately after arc extinction, then the welding process ends efficiently, but the stuck wire electrode causes counterforce to feeding and impairs arc ignition quality
Solution Approach 1:
The patent applies preliminary action by implementing a controlled current attenuation phase before complete shutdown. The welding current is gradually reduced to a low level (e.g., 1-10% of original current) over a predetermined time period (e.g., 10-100 milliseconds) after arc extinction, which prevents wire sticking to the tip while maintaining quick termination. This preliminary gradual reduction eliminates the harmful abrupt shutdown effect.
Solution Approach 2:
The patent applies dynamics by transitioning from static wire feeding to dynamic controlled feeding during termination. The wire feeding velocity is continuously adjusted during the attenuation phase, starting at normal feeding speed and gradually reducing to a lower speed or stopping. This dynamic adjustment ensures the wire is properly positioned and prevents sticking while maintaining productivity.
3Reliability
If the wire electrode is moved backwards to clean the tip, then the sticking problem is addressed, but the device complexity increases and operational time is extended
Solution Approach 1:
The patent applies parameter changes by modifying the electrical parameters (current magnitude and time) during the termination phase instead of adding mechanical complexity. By controlling the current to attenuate to a low level and maintaining wire feeding at a reduced velocity for a specific duration, the patent prevents sticking through parameter optimization rather than mechanical wire reversal or tip cleaning mechanisms.
Solution Approach 2:
The patent applies self-service by using the existing wire feeding mechanism to perform the detachment function. The same motor-driven feeding system that pushes the wire forward during welding is used in reverse or at reduced speed during termination to pull the wire away from the tip, eliminating the need for separate cleaning or reversal mechanisms.
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
Effectively reduces the sticking of the wire electrode to the welding current tip, ensuring reliable ignition and maintaining welding quality by loosening the electrode without damaging the tip, thus improving operational efficiency and reducing maintenance costs.
Implementation Method 1
an electric arc between a wire electrode, which is fed through a welding gun, and a work-piece is generated by means of an electric current supplied by a power source. The electric arc will melt the material to be welded
Implementation Method 2
The electric arc will melt the material to be welded and the wire electrode and fuse them, forming a molten weld pool
Data Source
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AI summary
The object of the invention is a method and an arrangement in a gas shielded arc welding device, such as a MIG/MAG-welder, for reducing the sticking of the wire electrode (1) to the welding current tip (3) of the welding torch (2) in connection with the termination of a welding step. The method utilizes a gas shielded arc welding device comprising a welding torch (2), a power source (4), wire feeding means (5), and a control means (7) for controlling at least the power source (4) and the wire feeding means (5). In connection with the termination of a welding step, a step of switching off the welding current is performed, wherein the welding current is switched off and the electric arc, as a consequence of the welding current being switched off, is extinguished, and a step of stopping the wire feeding is performed, wherein the wire feeding is stopped. After the performing of the step of switching off the welding current and the step of stopping the wire feeding, a step of post stop feeding is performed, wherein the wire electrode (1), by means of the wire feeding means (5), is being moved in relation to the welding current tip (3) of the welding torch (2).