Pivoted Wire Feed Positioning for Stable Welding Arc Deposition
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Solution Overview
Problem
Existing metal deposition techniques in solid freeform fabrication face challenges in maintaining the accurate positioning of a metal wire within the arc of a welding torch, leading to improper melting and deposition of metal, which affects the quality and efficiency of the manufacturing process, especially when working with expensive materials like titanium and nickel alloys.
Innovation Solution
A method involving a metal wire positioning system with a fixed main support frame and an adjustable guide support frame, rotatably connected by a pivot joint and supported by a rotatable piston, utilizing a motor and detector to precisely position the metal wire within the arc of the welding torch, ensuring continuous and accurate feeding of the metal wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed main frame support is used for the welding torch, then the stability of the welding position is improved, but the ability to adjust and maintain accurate wire placement is worsened
Solution Approach 1:
The patent applies the dynamics principle by making the guide support frame rotatably connected to the main frame via a pivot joint, allowing the system to transition from a completely fixed structure to one with controlled mobility. This enables real-time adjustment of wire placement accuracy while maintaining operational stability during the welding process.
Solution Approach 2:
The patent implements feedback through a detector that monitors the position of the wire relative to the welding arc and provides signals to a control system. This closed-loop feedback mechanism continuously adjusts the wire feed mechanism to maintain accurate wire placement within the arc, resolving the contradiction between stability and precision.
2Productivity
If the metal wire is fed at high speed to increase productivity, then the deposition rate is improved, but the positioning accuracy of the wire within the arc is worsened
Solution Approach 1:
The feedback principle is applied through a control system that receives position information from a detector and adjusts the wire feed speed dynamically. This allows the system to maintain high average deposition rates while making real-time corrections to ensure the wire remains accurately positioned within the welding arc, preventing quality degradation at high speeds.
Solution Approach 2:
The system dynamically adjusts wire feed parameters based on real-time positioning feedback, enabling the wire feed mechanism to operate at high speeds while maintaining precision through active control. The rotatable guide support frame also provides dynamic positioning capability to accommodate variations in wire delivery.
3Ease of manufacture
If a simple wire feed mechanism is used to reduce device complexity, then the ease of manufacture is improved, but the ability to maintain accurate wire positioning is worsened
Solution Approach 1:
The patent incorporates a detector and control system that provides feedback to the wire feed mechanism. This allows a relatively simple wire feed mechanism to achieve high positioning accuracy through intelligent control, rather than requiring complex mechanical precision. The feedback loop compensates for variations in wire properties and feed conditions.
Solution Approach 2:
The guide support frame acts as an intermediary element between the wire feed mechanism and the welding torch. It provides a rotatable connection that allows the simple wire feed mechanism to maintain accurate wire delivery by accommodating variations in wire tension, speed, and positioning through its rotational degree of freedom.
4Reliability
If the welding torch is kept fixed to improve stability, then the reliability is improved, but the flexibility to adjust for wire positioning errors is worsened
Solution Approach 1:
The patent applies dynamics by making the guide support frame rotatably connected to the fixed main frame. This creates a hybrid system where the welding torch remains fixed for stability, but the wire delivery path can dynamically adjust through the rotatable joint to compensate for positioning variations and maintain accurate wire placement within the arc.
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 enhances the deposition rate and accuracy of metal in solid freeform fabrication, maintaining the metal wire in the proper position within the welding torch's arc, thereby improving the efficiency and quality of the manufacturing process, particularly for materials like titanium and nickel alloys.
Implementation Method 1
a plasma transferred arc is formed between a non-consumable tungsten electrode and the welding area
Implementation Method 2
A plasma stream is created by energizing a flowing gas using an arc electrode
Data Source
Figure 1
AI summary
Provided is a method for continuously feeding a metal wire (180) to a welding torch in the correct orientation with respect to the heat source of the welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy, or nickel or nickel alloy, wire.