Pulse Arc Welding Wire Feed Control for Stable Droplet Transfer
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Solution Overview
Problem
Conventional pulse arc welding methods struggle to maintain the state of one pulse cycle-one droplet transfer, leading to variations in welding quality.
Innovation Solution
A method for controlling pulse arc welding that involves feeding a welding wire forward and backward, with specific current and speed modulation during different periods to stabilize the one pulse cycle-one droplet transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pulse arc welding is used with standard wire feeding, then welding process is simple, but welding quality varies and deviates from one pulse cycle-one droplet transfer state
Solution Approach 1:
The patent applies periodic action by implementing bidirectional wire feeding that synchronizes with the pulse cycle. The wire feeding direction changes periodically - feeding forward during peak current period and feeding backward during base current period - to maintain consistent one pulse cycle-one droplet transfer state despite welding state variations.
Solution Approach 2:
The patent implements dynamics by making the wire feeding system dynamically adjustable with two distinct feeding modes (forward and backward) that adapt to different phases of the pulse cycle. This dynamic control allows the system to respond to welding state variations and maintain precise droplet transfer control.
2Manufacturing precision
If wire feed speed is reduced during base period to maintain droplet transfer state, then welding quality improves, but productivity decreases
Solution Approach 1:
The patent uses periodic action by alternating wire feeding direction according to the pulse cycle phases. During peak current period, wire feeds forward to promote droplet formation and transfer. During base current period, wire feeds backward to control droplet detachment timing. This periodic bidirectional feeding maintains precise droplet transfer control while keeping the overall process efficient.
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
Maintains the state of one pulse cycle-one droplet transfer, ensuring consistent and excellent welding quality by synchronizing wire feed direction changes with current modulation.
Implementation Method 1
providing a peak rise current that rises from a value of a base current to a value of a peak current during a peak rise period, providing the peak current during a peak period, providing a peak fall current that falls from the value of the peak current to the value of the base current during a peak fall period
Data Source
AI summary
A method is provided for controlling pulse arc welding. The method includes feeding a welding wire, and providing a number of currents such as: a peak rise current that rises from a value of a base current to a value of a peak current during a peak rise period; the peak current during a peak period; a peak fall current that falls from the value of the peak current to the value of the base current during a peak fall period; and the base current during a base period. The method also includes repeating the provision of the currents as one pulse cycle to perform welding. The welding wire is fed forward and backward repeatedly, and is fed backward at least during the base period.