Pulse Arc Welding Control for Spatter Reduction and Arc Stability
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Solution Overview
Problem
Conventional pulse arc welding devices face challenges in maintaining high welding current while suppressing spatters and achieving stable arcs, especially at lower welding voltages, which can lead to undercut, humping, and prolonged short-circuit periods, delaying pulse-starting times and resulting in unstable arc conditions.
Innovation Solution
The method involves alternately supplying peak and base currents between the welding wire and base material, with a sharp decrease in welding current detected just before short circuit recovery and a subsequent increase upon recovery, using a device with a switching element, current and voltage detectors, and control sections to manage short-circuit and arc periods, thereby reducing spatters and stabilizing the arc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high welding current (250-350 A) is maintained to accelerate welding speed, then welding productivity increases, but undercut and humping occur and arc stability deteriorates
Solution Approach 1:
The patent applies periodic pulse action to the welding current, alternating between peak current (250-350 A) and base current periods. This periodic modulation allows the system to achieve high average welding speed while preventing continuous exposure to high current that causes undercut and humping, thereby maintaining arc stability through rhythmic current variation
Solution Approach 2:
The patent dynamically adjusts welding current parameters by switching between different current levels (peak and base) and controlling pulse timing. The pulse width, duty cycle, and current magnitude are dynamically modified based on welding conditions, enabling acceleration of welding speed while preventing defects through real-time parameter adaptation
2Manufacturing precision
If lower welding voltage is set to avoid undercut and humping, then manufacturing precision improves, but short-circuit period is prolonged and pulse-starting time is delayed
Solution Approach 1:
The patent applies preliminary action by pre-setting optimized pulse parameters (peak current level, pulse width, and timing) before welding begins. The control system is pre-configured with parameter combinations that achieve quick short-circuit recovery, ensuring that even at lower voltages, the pulse can start promptly without excessive delay, thus preventing productivity loss while maintaining welding quality
3Manufacturing precision
If lower welding voltage is used to prevent undercut and humping, then manufacturing precision improves, but spatter amount increases
Solution Approach 1:
The patent changes electrical parameters by introducing pulse current modulation with specific peak current levels and duty cycles. This parameter transformation allows the system to operate at lower average voltages (reducing undercut and humping) while using high peak currents in controlled pulses to minimize spatter generation, thus simultaneously improving welding quality and reducing harmful spatter
4Reliability
If pulse width is increased to maintain stable arc, then arc stability improves, but welding speed decreases
Solution Approach 1:
The patent employs periodic pulse action with optimized pulse width and duty cycle parameters. By using short high-current pulses followed by base current periods, the system maintains arc stability during peak pulses while achieving high average welding speed through the periodic nature of the current application, thus resolving the trade-off between pulse width and welding speed
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 effectively reduces spatter formation and maintains a stable arc even at high welding currents, accelerating welding speed without compromising arc stability, by controlling the current gradient and duration during short-circuit periods.
Implementation Method 1
a pulse arc welding device... alternately feeding peak current and base current between a wire and a welding base material
Data Source
AI summary
Disclosed here is a pulse welding control method and a pulse arc welding device capable of improving arc stability, and decreasing the amount of spatters. The structure contains arc short-circuit judging section (13) for judging a welding state; setting section (21) for defining parameters used for a short-circuit period and an arc period; secondary control section (25); and driving section (18). Secondary control section (25) sharply decreases welding current on detecting a moment when the tip of a wire has a neck just before recovery from the short circuit, according to at least any one of outputs from a welding current value detector, a welding voltage value detector, and the setting section. Driving section (18) selects from outputs of a pulse-waveform circuit section and a dip-waveform circuit section according to the signal from the setting section and the output from the arc short-circuit section, and outputs the selected data to a switching element.