Piezoelectric Wire Feed Actuator for Welding Torque and Overheating
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Solution Overview
Problem
Traditional reciprocating wire feed systems in welding, particularly those using bidirectional motors, face limitations in torque requirements, frequency of wire feed, and are prone to overheating, which restricts welding speed and productivity and can cause accessibility issues in weld joint formation.
Innovation Solution
The implementation of piezoelectric mechanisms such as piezoelectric walk motors, worm drives, wave drives, shape memory alloys, solenoid pistons, linear actuators, or voice coil actuators to drive the welding wire, which reduce torque requirements, enable higher frequency changes, and are less susceptible to overheating, allowing for improved wire feed systems that can be retrofitted into existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bidirectional motors are used to drive reciprocating wire feed, then wire feed capability is achieved, but torque requirements become excessively high and the system is prone to overheating
Solution Approach 1:
The patent replaces the traditional bidirectional motor mechanical system with a piezoelectric actuator system. The piezoelectric actuator converts electrical energy directly to mechanical motion through ceramic element expansion and contraction, eliminating the need for high-torque mechanical motors and associated gears, thereby reducing overheating and energy loss.
Solution Approach 2:
The patent changes the fundamental operating parameters by using piezoelectric actuators that operate at higher frequencies with lower force requirements compared to traditional motors. The ceramic elements expand and contract rapidly in response to voltage changes, enabling wire feed at frequencies exceeding 100 Hz without the torque limitations of mechanical motors.
2Productivity
If traditional bidirectional motors are used for wire feed, then wire delivery is achieved, but the reciprocating frequency is limited which restricts welding speed
Solution Approach 1:
The patent replaces the motor-driven mechanical system with piezoelectric actuators that can operate at significantly higher frequencies. The direct conversion of electrical to mechanical energy in piezoelectric ceramics eliminates mechanical inertia and gear limitations, enabling reciprocating frequencies in excess of 100 Hz which directly increases welding speed and productivity.
3Ease of operation
If bidirectional motors with gears are used, then wire feed is achieved, but the system size increases causing weld joint accessibility issues
Solution Approach 1:
The patent replaces the bulky motor-gear assembly with compact piezoelectric actuators. The piezoelectric ceramic elements that expand and contract to drive wire feed are significantly smaller than equivalent mechanical motor systems, reducing the overall actuator size and improving accessibility to confined weld joints.
4Productivity
If traditional wire feed systems are used, then basic wire delivery is achieved, but deposition rate and welding travel speed are restricted
Solution Approach 1:
The patent changes the operational parameters by using piezoelectric actuators capable of higher frequency reciprocating motion. This enables the wire to be fed into the weld puddle and pulled out at rates exceeding 1000 inches per minute at 100 Hz, significantly increasing both deposition rate and welding travel speed compared to traditional systems.
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
These piezoelectric-based wire feed systems enhance arc starting, reduce spatter, increase travel speeds, improve weld grain refinement, and increase ductility, while allowing for higher deposition rates and faster welding speeds with improved accessibility to weld joints.
Implementation Method 1
A piezoelectric mechanism, such as a piezoelectric walk motor, piezoelectric worm drive, piezoelectric wave drive, has been configured to transform electrical energy to mechanical energy in a non-rotational manner
Implementation Method 2
A piezoelectric mechanism, such as a piezoelectric walk motor, piezoelectric worm drive, piezoelectric wave drive, shape memory alloy, solenoid piston, linear actuator, or voice coil actuator
Implementation Method 3
A piezoelectric mechanism, such as a piezoelectric walk motor, piezoelectric worm drive, piezoelectric wave drive, shape memory alloy, solenoid piston, linear actuator, or voice coil actuator
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A welding wire delivery system includes a non-rotational actuator (58) configured to engage, disengage, and move welding wire (42). In certain embodiments, the welding wire (42) delivery system includes a piezoelectric walk motor, a piezoelectric worm drive, a piezoelectric wave drive, a shape memory alloy, a solenoid piston, a linear actuator (125) or motor, or a voice coil actuator.