Pulse Welding Voltage Control for Quieter Arc Waveforms
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Solution Overview
Problem
Conventional pulse welding processes produce weld current and voltage waveforms with sharp edges, leading to unpleasant noise due to the presence of odd harmonic frequencies, which can be bothersome during welding operations.
Innovation Solution
The implementation of a voltage-controlled pulse welding system that rounds the edges of the weld current waveform by using different inductance parameters and target voltages during various phases of the pulse cycle, allowing for a smoother transition between the background, ramp up, peak, and ramp down phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pulse welding processes are used with abrupt current changes, then welding efficiency is maintained, but unpleasant noise is generated due to odd harmonic frequencies
Solution Approach 1:
The patent applies dynamics by making the inductance value variable rather than fixed. The controller dynamically adjusts the inductance parameter during different phases of the pulse cycle - using a first inductance value during background and peak phases, and a second inductance value during ramp-up and ramp-down phases. This dynamic adjustment smooths the current waveform transitions, reducing odd harmonic content and noise while maintaining welding efficiency.
Solution Approach 2:
The patent changes the inductance parameter at different stages of the pulse cycle. By switching between a first inductance value and a second inductance value, the system modifies the electrical parameters to control the rate of current change. This parameter change approach reduces the abruptness of current transitions, thereby reducing odd harmonic frequencies and associated noise while preserving productive welding performance.
2Device complexity
If abrupt current transitions are used in pulse welding, then process simplicity is maintained, but noise from odd harmonic frequencies increases
Solution Approach 1:
The controller dynamically selects between different inductance values based on the current phase of the pulse cycle. This dynamic approach provides a relatively simple control mechanism that effectively reduces odd harmonics without requiring complex additional hardware or overly complicated control algorithms.
Solution Approach 2:
The system uses parameter changes in inductance value to control the current waveform shape. By switching between a first inductance value during background/peak phases and a second inductance value during transition phases, the system achieves noise reduction through relatively simple parameter modulation rather than complex control schemes.
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 reduces the magnitude of odd harmonics, resulting in a quieter and less unpleasant-sounding arc, improving the overall welding experience by minimizing noise during the welding process.
Implementation Method 1
power conversion circuitry configured to convert input power to welding-type power
Implementation Method 2
control circuitry configured to control the power conversion circuitry
Data Source
AI summary
Systems and methods to control pulse welding are disclosed. An example welding-type system includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to control the power conversion circuitry to output the welding-type power in a plurality of pulse cycles, each pulse cycle including background, ramp up, peak, and ramp down phases. Controlling the power conversion circuitry involves: during the background phase, controlling the power conversion circuitry in a voltage-controlled mode using a background voltage as a target voltage; during the ramp up phase, controlling the power conversion circuitry by changing the target voltage to a peak voltage; during the peak phase, controlling the power conversion circuitry using the peak voltage as the target voltage; and during the ramp down phase, controlling the power conversion circuitry by changing the target voltage to the background voltage.