Pulse Arc Welding Wire Feed Control for Low-Spatter Short Circuits
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Solution Overview
Problem
Pulse arc welding experiences increased spatter due to short circuits between the welding wire and the base material, leading to poor welding quality.
Innovation Solution
A method and power supply for pulse arc welding that controls the feeding of the welding wire forward and backward, adjusts current phases, and modulates feed speed to manage short circuits, including delaying the start of the peak rise period until the short circuit is cleared and maintaining reverse-feeding during the short circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding wire is fed forward at a high speed during the base period to generate short circuits, then the droplet transfer is promoted, but the amount of spatter increases when short circuits occur
Solution Approach 1:
The patent applies dynamics by making the feed speed variable rather than constant. The feed speed is dynamically adjusted based on the welding phase (peak or base period) and short circuit detection. During the base period, the wire is fed forward at a higher speed to promote droplet transfer, while during the peak period or when short circuits are detected, the feed speed is reduced or reversed to suppress spatter. This dynamic adjustment resolves the contradiction between welding efficiency and spatter reduction.
Solution Approach 2:
The patent changes the feed speed parameter according to different welding conditions. By detecting short circuits through voltage monitoring and adjusting the feed speed parameter accordingly (reducing it when short circuits occur), the system optimizes both productivity and spatter control. The feed speed parameter is modified based on the phase of the pulse cycle and real-time short circuit detection, allowing the system to achieve high welding efficiency while minimizing spatter.
2Manufacturing precision
If the feed speed is reduced during the base period to generate short circuits, then droplet transfer is improved, but welding quality deteriorates due to increased spatter
Solution Approach 1:
The patent implements feedback control by monitoring the welding voltage to detect short circuits. When a short circuit is detected through voltage monitoring, the system provides feedback to the feed speed control mechanism, which then adjusts the feed speed to reduce spatter. This closed-loop feedback system ensures that welding quality is maintained by automatically responding to short circuit conditions and adjusting parameters in real-time to minimize harmful spatter effects.
Solution Approach 2:
The patent applies preliminary anti-action by proactively reducing the feed speed or reversing the feed direction when a short circuit is detected. Instead of allowing spatter to occur and then correcting it, the system takes preventive action by adjusting the feed speed before significant spatter can generate. This anticipatory control mechanism helps maintain welding quality by preventing excessive spatter formation in the first place.
3Productivity
If the peak rise period starts immediately, then the welding cycle efficiency is maintained, but spatter increases when short circuits occur during the rise period
Solution Approach 1:
The patent applies dynamics by making the timing of the peak rise period flexible rather than fixed. The start of the peak rise period is dynamically delayed when a short circuit is detected during the base period. This dynamic timing adjustment allows the system to maintain overall cycle efficiency by only delaying the peak rise when necessary (during short circuits), while still achieving spatter reduction by preventing high-current operation during problematic short circuit conditions.
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 significantly reduces spatter occurrence, enhancing welding quality by stabilizing the arc and controlling the feed speed to maintain consistent welding parameters.
Implementation Method 1
providing a peak rise current that rises from the value of a base current to the value of a peak current during a peak rise period
Implementation Method 2
providing the peak current during a peak period
Data Source
AI summary
A method for controlling pulse arc welding includes repeating provisions of welding currents during a peak rise period, a peak period, a peak fall period, and a base period as one pulse cycle, and performing arc length control based on a welding voltage setting value. The feed speed of the welding wire is set to: a forward-feeding peak value during the peak period; a base period forward-feeding value during the base period to generate a short circuit, where the base period forward-feeding value is smaller than the forward-feeding peak value; and a reverse-feeding peak value when the short circuit occurs. The reverse-feeding peak value is maintained after the short circuit is cleared.