Model-Based Wire Preheating in Welding Power Supplies
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Solution Overview
Problem
Existing welding power supplies face challenges in accurately preheating electrode wires to target temperatures without temperature measurements, especially due to the difficulty in measuring wire temperature within welding torches.
Innovation Solution
The development of welding power supplies that utilize a temperature model to preheat electrode wires to a target temperature, based on material properties and process parameters, without the need for temperature sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are used to measure wire temperature, then temperature control accuracy is improved, but device complexity and difficulty of measurement increase
Solution Approach 1:
The patent replaces physical temperature sensors with an optical measurement system using a camera to capture wire temperature through color/temperature mapping. This substitutes mechanical/electrical sensing with optical detection, eliminating the need for contact sensors in the welding torch while achieving accurate temperature measurement.
Solution Approach 2:
The patent introduces an intermediary optical system (camera and temperature mapping algorithm) between the wire and the measurement system. Instead of directly measuring wire temperature with sensors, the system captures optical information and converts it to temperature data through calibration and processing.
2Reliability
If separate preheating power supply is used, then preheating reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the preheating power supply and welding power supply into a single integrated power supply unit. This merging eliminates the need for separate preheating equipment while maintaining reliable temperature control through unified power management and coordination between preheating and welding operations.
Solution Approach 2:
The power supply is designed to perform multiple functions: it can operate as a preheating power supply, a welding power supply, or both simultaneously. This multi-functionality allows a single device to replace what would traditionally require separate specialized equipment.
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 allows for accurate and reliable preheating temperature control, reducing development time for welding processes and enabling better manipulation of preheat and welding energy balances.
Implementation Method 1
a power conversion circuitry (30) converts the input power (22) to a welding power and to a wire preheating power
Implementation Method 2
controls the power conversion circuitry (30) to preheat the electrode wire (54) by converting at least a portion of the input power (22) to the wire preheating power
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An example welding power supply includes: power conversion circuitry configured to convert input power to wire preheating power, and to output the wire preheating power to a preheating system; and control circuitry configured to control the power conversion circuitry based on a temperature model to preheat an electrode wire to a target temperature via the preheating system.