Push-Pull Wire Feed Control for Stable Arc Welding Response
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Solution Overview
Problem
Conventional arc welding methods using forward/reverse feeding face challenges in maintaining consistent welding quality due to abrupt changes in welding conditions, leading to fluctuations in average feeding speed and deposition amount, which are not adequately addressed by existing correction controls.
Innovation Solution
A control method that corrects and controls the pull feeding speed based on the store amount in the intermediate wire receptacle, adjusting waveform parameters such as forward- and reverse-feeding peak values to maintain consistent feeding speed and improve transient responsiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional correction control changes the average value of pull feeding speed based on store amount, then the control system is simple to implement, but the transient responsiveness deteriorates when welding conditions change abruptly
Solution Approach 1:
The patent changes the control parameter from average pull feeding speed to waveform parameters (peak values, pulse widths) of the pull feeding speed. This allows direct adjustment of the speed waveform in response to store amount changes, achieving fast transient responsiveness while maintaining a relatively simple control structure through parameter optimization rather than system redesign.
Solution Approach 2:
The patent pre-establishes the relationship between store amount and waveform parameters through offline optimization or lookup tables. When welding conditions change, the system quickly retrieves or calculates the appropriate waveform parameters in advance, enabling rapid response without complex real-time computation, thus achieving fast transient responsiveness with simple online control.
2Adaptability or versatility
If the average feeding speed changes due to changes in welding conditions, then the deposition amount changes, but the welding quality deteriorates
Solution Approach 1:
The patent implements a feedback control mechanism where the store amount in the intermediate wire receptacle is continuously monitored. Based on the detected store amount, the pull feeding speed waveform parameters are dynamically adjusted to maintain consistent average feeding speed and deposition amount, ensuring stable welding quality despite changes in welding conditions.
Solution Approach 2:
The patent adjusts waveform parameters (peak values, pulse widths) of the pull feeding speed based on store amount feedback. This dynamic parameter adjustment compensates for changes in average feeding speed caused by varying welding conditions, maintaining consistent deposition amount and welding quality while adapting to different operating scenarios.
3Reliability
If forward/reverse feeding is used to stabilize short-circuit and arc periods, then welding quality improves, but the average feeding speed becomes sensitive to welding condition changes
Solution Approach 1:
The patent dynamically adjusts the waveform parameters of pull feeding speed based on store amount feedback. This allows the system to maintain the benefits of forward/reverse feeding for stabilizing the welding process while compensating for changes in average feeding speed caused by varying welding conditions, thus maintaining both process stability and feeding speed consistency.
Solution Approach 2:
The patent uses store amount feedback to monitor and adjust the pull feeding speed waveform. This feedback mechanism ensures that the average feeding speed remains consistent even when welding conditions change, preventing deterioration in welding quality while maintaining the stability benefits of forward/reverse feeding through continuous adaptation.
Data Source
AI summary
A control method is provided for arc welding performed by repeating a short-circuit period and an arc period. The method includes: feeding a welding wire by a push-pull feeding control using a push-side feeding motor configured to rotate in a forward direction and a pull-side feeding motor configured to rotate in a forward direction and a reverse direction; temporarily storing a portion of the welding wire in an intermediate wire receptacle disposed along a feeding path between the push-side feeding motor and the pull-side feeding motor; and correcting a pull feeding speed of the pull-side feeding motor based on a store amount of the welding wire in the intermediate wire receptacle. The correction of the pull feeding speed is performed by correcting a waveform parameter for the pull feeding speed based on the store amount in the intermediate wire receptacle.