Parallel State-Based Controller for Arc Welding Power Supply
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Solution Overview
Problem
Current arc welding systems lack integration between state-based welding controllers and separate motion controllers, leading to inefficiencies and instabilities due to disparate control frequencies and the need for duplicate sensors, which hinders precise control over welding waveforms and torch movements.
Innovation Solution
A parallel state-based controller is introduced that simultaneously controls the welding waveform and torch movements using a single processor, integrating welding and motion control through shared state tables and feedback signals, allowing for synchronized transitions between control states based on welding voltage and current signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate additional controllers are provided for controlling motion and welding parameters, then dedicated control functions are achieved, but device complexity increases and integration between controllers is poor
Solution Approach 1:
The patent combines the welding controller and motion controller into a single integrated controller that executes both welding control instructions and motion control instructions. This merging eliminates the need for separate dedicated controllers while maintaining all required control functions, thereby reducing device complexity without sacrificing adaptability.
Solution Approach 2:
The integrated controller is designed to perform multiple functions by processing both welding parameters and motion commands through a unified control architecture. The controller universally handles different control tasks using shared hardware resources and a common processing core, enabling one device to replace multiple specialized controllers.
2Stability of the object's composition
If separate additional controllers operate at slower control frequencies, then system stability is maintained, but control precision and responsiveness deteriorate
Solution Approach 1:
The integrated controller dynamically adjusts control frequencies for different functions based on real-time requirements. It can execute welding control at high frequencies when precision and responsiveness are critical, while maintaining system stability through adaptive frequency management that responds to actual process conditions rather than operating at fixed slow speeds.
Solution Approach 2:
The controller changes operational parameters including control frequency dynamically during operation. By adjusting the frequency of control signal generation based on the specific control task and system state, the controller achieves both high-speed responsive control when needed and stable operation when conditions require it, eliminating the trade-off between speed and stability.
3Reliability
If duplicate sensors are used in separate controllers, then each controller has independent sensing capability, but system cost and complexity increase
Solution Approach 1:
The integrated controller merges the sensing functions of previously separate controllers into a single unified sensing system. The controller uses shared sensors for both welding parameter monitoring and motion control feedback, eliminating duplicate sensor installations while maintaining the reliability needed for both control functions through centralized signal processing.
Solution Approach 2:
The sensing system in the integrated controller is designed with universal capability to serve multiple control functions simultaneously. A single set of sensors provides data that the controller processes for both welding parameter regulation and motion control, making the sensing subsystem multi-functional rather than requiring separate dedicated sensors for each control task.
4Ease of operation
If separate controllers are used with little integration, then each controller operates independently, but synergy and overall system efficiency are reduced
Solution Approach 1:
The patent merges previously separate welding and motion controllers into a single integrated control system that processes both control instructions simultaneously. This combination enables synergistic interaction between welding and motion control functions, allowing the system to optimize overall performance and productivity while maintaining the operational independence needed for ease of control through a unified interface.
Data Source
AI summary
An arc welding system includes a welding torch, an electrode, and a power supply having a switching-type power converter connected to the torch. A parallel state-based controller is connected to the power converter and provides a waveform control signal thereto for controlling its operations. The controller generates a motion control signal for controlling movements of the electrode and/or the torch. A sensor senses welding voltage or welding current. A memory stores a welding state table comprising sequential control states, and stores a motion control system state table comprising further sequential control states. The welding waveform is defined in the welding state table. The controller controls the operations of the power converter through the waveform control signal according to the welding state table, simultaneously adjusting the motion control signal according to the motion control system state table. The controller transitions between control states according to the signal received from the sensor.