Multiple Pulse Welding Synchronization for Stable Arc Control
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Solution Overview
Problem
In multiple pulse welding methods, achieving ideal welding conditions is challenging due to unsynchronized pulse frequencies and wire feeding speeds between welding processes, leading to instability and poor welding quality.
Innovation Solution
The method synchronizes pulse welding processes by adjusting the pulse frequency ratio between leading and following processes, allowing for optimal droplet detachment and constant arc length through control of root-mean-square welding current and wire feeding speed, with the ability to fine-tune welding parameters for ideal settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pulse welding processes are operated independently with individually set parameters, then each process can be optimized for its specific requirements, but the setting time increases and mutual interference reduces welding quality
Solution Approach 1:
The patent applies parameter changes by deriving the pulse frequency of the second welding process from the first pulse frequency using a predefined integer ratio. This automatic parameter derivation eliminates manual setting time while maintaining optimal parameters for each welding process, resolving the contradiction between adaptability and time loss.
2Stability of the object's composition
If the pulse frequency of the following welding process is set to match the leading process, then synchronization is achieved, but droplet detachment and arc stability may be compromised due to unsuitable frequency for the specific welding parameters
Solution Approach 1:
The patent applies dynamics by allowing the pulse frequency of the following welding process to be dynamically adjusted based on a predefined integer ratio to the leading process frequency. This enables the system to maintain synchronization while adapting to different welding parameters, ensuring both stability and reliability through flexible frequency derivation rather than fixed matching.
3Reliability
If the welding wire feeding speed is reduced to improve process stability, then droplet formation is improved, but the required pulse frequency must also be reduced which may not be achievable due to synchronization constraints
Solution Approach 1:
The patent applies segmentation by using a predefined integer ratio relationship between the pulse frequencies of the leading and following welding processes. This segmentation allows independent optimization of each process's pulse frequency and wire feeding speed while maintaining a structured relationship between them, enabling flexibility in adjusting parameters for stability without compromising the overall system coordination.
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 ensures stable and high-quality welding results by maintaining optimal welding conditions across all processes, reducing weld spatter and improving process stability.
Implementation Method 1
During the base welding current phase, the arc burns at low power in order to keep the weld pool liquid. During the pulsed current phase, a droplet of the filler material supplied as a welding wire forms that is ultimately detached and drops into the weld pool.
Implementation Method 2
During the pulsed current phase, a droplet of the filler material supplied as a welding wire forms that is ultimately detached and drops into the weld pool.
Data Source
AI summary
Method and arrangement for carrying out a multiple pulse welding method in which an ideal ratio between the root-mean-square value of the welding current and the welding wire feeding speed is determined from a known relationship between the pulse frequency and the welding wire feeding speed, an actual root-mean-square value of the welding current is determined by the welding current with the pulse frequency to be set, and at least one pulsed current parameter of the welding current of the pulse welding process and/or the welding wire feeding speed of the pulse welding process is changed in order to change the actual ratio to the ideal ratio.