Serial Digital Welding Communication via Master-Slave Segmentation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing arc welding systems face challenges in achieving reliable digital communication, flexibility in system layout, and accurate arc tracking due to limitations in analog communication, which lead to reduced reliability and increased complexity with digital communication using parallel bus systems.

Innovation Solution

The implementation of a serial digital communication system between the welding power supply and controller, utilizing a single communication path with synchronous control through welding power-supply sync and robot sync signals, ensuring high reliability and flexibility in system design, and enabling accurate arc tracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If digital communication using parallel bus system is used, then communication speed and data amount are improved, but communication reliability and system layout flexibility deteriorate

Engineering Contradiction:

Improvecommunication data amountVSAvoidcommunication reliability

Core Design Contradiction:

Loss of informationVSReliability

Solution Approach 1:

The communication path is segmented into a master station and slave stations with hierarchical control. The master station coordinates communication timing and data exchange, while slave stations provide feedback signals. This segmentation allows digital communication with reduced cable length requirements compared to parallel bus systems, while maintaining reliability through structured communication protocols.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The master station acts as an intermediary that coordinates communication between the welding power supply and controller. It manages the communication protocol, timing synchronization, and data exchange, enabling reliable digital communication without requiring complex parallel bus wiring.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Speed

If digital communication using parallel bus system is used, then communication speed is improved, but cable length restriction and system layout flexibility worsen

Engineering Contradiction:

Improvecommunication speedVSAvoidsystem layout flexibility

Core Design Contradiction:

SpeedVSAdaptability or versatility

Solution Approach 1:

The communication system is divided into master and slave stations with defined roles. This segmentation enables the use of shorter cables between components while maintaining communication effectiveness, thereby increasing system layout flexibility and adaptability to different welding configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The communication protocol parameters are optimized for the serial communication architecture, allowing effective data transmission over shorter cable lengths. This enables greater system layout flexibility compared to parallel bus systems that require longer cables to maintain signal integrity across multiple channels.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If analog communication is used, then communication reliability is improved, but communication data amount and sophistication capability worsen

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidcommunication data amount

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The system replaces analog communication mechanisms with digital communication mechanisms. The master-slave station architecture with synchronous control signals enables digital data exchange that maintains reliability while increasing the amount and sophistication of communicable information, allowing for more advanced welding control and monitoring capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If synchronous control with sampling at fixed intervals is implemented, then arc tracking accuracy is improved, but real-time performance requirement increases

Engineering Contradiction:

Improvearc tracking accuracyVSAvoidreal-time performance

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system implements periodic sampling at fixed intervals using synchronous control signals from the master station. This periodic action ensures consistent arc tracking accuracy by sampling welding parameters at regular intervals, while the coordinated master-slave architecture manages the timing to maintain overall system real-time performance.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Slave stations provide feedback signals to the master station at fixed intervals, enabling the system to maintain accurate arc tracking through periodic measurement and correction. The feedback mechanism ensures that position deviations are detected and corrected systematically, maintaining tracking accuracy while managing real-time performance requirements.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS8653412B2Arc welding system, single arc welding system, and tandem arc welding system

Publication Date: 2014.02.18 KOBE STEEL LTD

AI summary

An arc welding system according to the present invention includes a welding power supply for supplying welding power to a welding wire, a welding robot including a welding torch mounted to an arm fore end thereof, and a controller for controlling the welding power supply and the welding robot. The welding power supply and the controller perform communication using digital signals, and the welding power supply outputs, to the controller, a welding power-supply feedback signal obtained at the time of inputting of a welding power-supply sync signal. With that configuration, accurate arc tracking can be realized by using the digital signals.