Push-Pull Wire Feed Control for Bird-Nesting-Free Welding
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Solution Overview
Problem
Conventional welding wire feeding systems require empirical settings and constant calibration to prevent bird-nesting and shaving, especially when feeding aluminum wire, and often necessitate specialized equipment, which is inconvenient and not universally applicable.
Innovation Solution
A push-pull welding system with a push motor and a pull motor, where the push motor is coupled with a tachometer or current sensor, and control circuitry monitors and adjusts the motor parameters to maintain a fixed operating speed and torque, eliminating the need for empirical settings and calibration by actively controlling the torque and speed of the pull motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wire feeding systems are used, then the system structure is simple, but empirical settings and constant calibration are required to prevent bird-nesting and shaving
Solution Approach 1:
The patent implements feedback control by monitoring the actual wire feed rate and comparing it to the target wire feed rate, then adjusting motor parameters accordingly. This closed-loop feedback mechanism eliminates the need for empirical settings and constant calibration while maintaining reliable wire feeding without bird-nesting or shaving.
Solution Approach 2:
The control system performs self-adjustment by automatically modifying motor torque and speed based on real-time wire feed rate measurements. The system serves itself by eliminating the need for external calibration or empirical settings, adapting to varying conditions autonomously.
2Reliability
If multiple wire feed motors are used, then wire feeding reliability improves, but the device complexity increases
Solution Approach 1:
The patent combines the control of push motor and pull motor into a unified control system that coordinates both motors based on a single target wire feed rate. This merging of control functions reduces overall system complexity while maintaining the reliability benefits of multiple motors.
Solution Approach 2:
The control system dynamically adjusts motor parameters (torque for pull motor, speed for push motor) based on real-time conditions and actual wire feed rate measurements. This dynamic adaptation allows the system to maintain reliability without requiring complex static configurations or calibration procedures.
3Ease of manufacture
If empirical settings are used for motor control, then the setup process is simple, but manufacturing precision deteriorates due to bird-nesting and shaving
Solution Approach 1:
The patent replaces mechanical calibration and empirical setting procedures with an electronic feedback control system. The system automatically determines optimal motor parameters through real-time monitoring and adjustment, eliminating the need for manual mechanical setup while achieving precise wire feeding without bird-nesting or shaving.
4Manufacturing precision
If constant calibration is performed, then wire feeding precision is maintained, but loss of time increases
Solution Approach 1:
The feedback control system operates continuously during wire feeding operations, constantly monitoring and adjusting motor parameters to maintain precision. This eliminates the need for periodic stopping and recalibration, as precision is maintained throughout the entire welding process without interruption or time loss.
Data Source
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AI summary
A system for controlling multiple wire feed motors for use in a welding-type system including a push motor controlled to operate at a target wire feed speed and a pull motor disposed in a welding torch controlled to apply a target torque to the fed welding wire. Such a system eliminates shaving and bird nesting of welding wire.