Pulse Arc Welding Profile Control for Accurate Groove Tracking
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Solution Overview
Problem
Existing pulse arc welding profile control methods fail to accurately extract protruding change information due to the influence of pulse-shaped welding current and arc voltage, leading to reduced welding line profile accuracy.
Innovation Solution
A pulse arc welding profile control method that calculates an average value of electric change amounts over a predetermined period, incorporating both welding current and arc voltage detection signals, and uses this average value to follow the welding line, thereby extracting protruding change information with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pulse arc welding is used to perform welding by periodically changing welding current and arc voltage, then welding efficiency and penetration control are improved, but the periodic pulse waveform causes inaccurate extraction of protruding change information, reducing profile control accuracy
Solution Approach 1:
The patent segments the pulse waveform into distinct phases (peak current phase and base current phase) and performs separate measurements for each phase. By dividing the measurement into these segments, the system can isolate and analyze the protruding change information specific to each phase, eliminating the interference caused by the periodic pulse waveform and achieving accurate profile control while maintaining high welding efficiency
Solution Approach 2:
The patent changes the measurement parameters by detecting welding current and arc voltage at different phases of the pulse waveform. Instead of using a single fixed measurement point, the system adjusts the detection timing to capture data during both peak and base current phases, thereby extracting accurate protruding change information despite the periodic variation in welding parameters
2Device complexity
If the value at peak position or base position in the pulse waveform is used for detection, then the detection process is simplified, but the sampling period causes inaccurate detection of welding current and arc voltage, leading to poor extraction of torch protruding change information
Solution Approach 1:
The patent divides the detection process into two distinct segments: one for the peak current phase and another for the base current phase. Each segment uses optimized detection parameters suitable for its specific phase characteristics, allowing accurate extraction of protruding change information without requiring complex real-time processing of the entire pulse waveform
Solution Approach 2:
The patent performs preliminary detection of welding current and arc voltage at predetermined timing points during each pulse cycle. By capturing data in advance at these critical moments, the system prepares the necessary information for accurate protruding change calculation, reducing the need for complex real-time processing while maintaining high measurement precision
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 approach enables highly accurate welding line profile control by isolating the influence of pulse-shaped welding current and arc voltage, resulting in improved precision and accuracy of the welding process.
Implementation Method 1
The arc sensor utilizes the characteristic that when the distance (hereinafter also referred to as the 'distance between tip and base material' or 'protruding') between a current-carrying point (a contact point between a welding wire and a contact tip) of a welding wire and a base material changes, a welding current and an arc voltage change accordingly.
Implementation Method 2
a welding current and an arc voltage change accordingly
Data Source
AI summary
A pulse arc welding profile control method, a control device, a welding system, a welding program, and a welding power supply are provided in which, even when a pulse arc welding method is used, protruding change information is extractable at high accuracy without influence from a welding current or an arc voltage having a pulse shape. An electric change amount detected at the time of weaving includes, as a parameter, at least one among a welding current detection signal and an arc voltage detection signal, takes a predetermined period as one period, calculates an average value of the electric change amount in each one period, and extracts, on the basis of the average value, the protruding change information in a groove to follow a welding line.