Short-Circuit Welding Wire Speed Control for Stable Arc Transfer
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Solution Overview
Problem
Short-circuit welding methods experience variability in short-circuit occurrences and breaks, leading to inconsistent welding frequency and quality, particularly with materials like chromium-nickel alloys and titanium, often resulting in unwanted splashes due to inappropriate welding wire speed.
Innovation Solution
Adaptive feedforward and feedback control systems adjust the duration of the first rearward conveying phase to ensure the welding wire reaches a reduced speed before short-circuit interruption, preventing excessive speed and splashes, and stabilizing the welding frequency by implementing intermediate plateau phases with constant speeds during material transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding wire speed is increased to improve productivity, then welding frequency increases, but welding splashes occur and welding quality deteriorates
Solution Approach 1:
The patent applies dynamics by making the welding wire speed variable rather than constant. The control system continuously adjusts the wire speed during the welding process, specifically reducing speed during the short-circuit phase and increasing it during the arc phase. This dynamic speed adjustment prevents splashes while maintaining high welding frequency, resolving the contradiction between productivity and quality.
Solution Approach 2:
The patent changes the speed parameter of the welding wire based on the welding phase. By modifying the wire speed parameter in real-time according to whether the system is in arc phase or short-circuit phase, the invention achieves both high productivity and splash-free welding. The speed parameter is adjusted to match the instantaneous requirements of the welding process.
2Object-generated harmful factors
If the welding wire speed is decreased to avoid splashes, then welding quality improves, but welding frequency decreases and productivity reduces
Solution Approach 1:
The patent implements periodic action by alternating between different wire speed regimes corresponding to the periodic nature of short-circuit welding cycles. The wire speed is reduced during short-circuit phases and increased during arc phases in a regular, cyclical pattern. This periodic speed modulation allows the system to maintain high average welding frequency while preventing splashes during critical material transfer moments.
Solution Approach 2:
The dynamic adjustment of wire speed allows the system to optimize for splash prevention during short-circuit phases while recovering productivity during arc phases. The wire speed is not statically reduced but dynamically modulated to match process requirements, maintaining high overall welding frequency without sacrificing splash control.
3Device complexity
If fixed predetermined speeds are used for welding wire conveying, then device complexity is reduced, but welding frequency becomes unstable and quality deteriorates
Solution Approach 1:
The patent applies feedback control by using sensors to detect the actual welding parameters and wire position, then using this information to adjust the wire speed in real-time. The control system receives feedback about the welding state and modifies the conveying speed accordingly, ensuring stable welding frequency and high quality without requiring overly complex mechanical systems.
Solution Approach 2:
The patent replaces complex mechanical speed control mechanisms with electronic/control-based speed adjustment. Instead of using complex mechanical transmissions or variable speed drives, the invention uses controllable wire feed mechanisms with electronic control, simplifying the mechanical system while achieving precise, stable speed regulation for consistent welding frequency.
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 stabilizes the welding frequency, reduces splashes, and enhances welding quality by precisely controlling the welding wire speed, even with viscous materials, by adjusting the conveying phase durations based on real-time measurements and predictions.
Implementation Method 1
conveying a melting welding wire away from a workpiece during the short-circuit phase
Implementation Method 2
generate a short-circuit between the welding wire and the workpiece
Implementation Method 3
During the arc phase, thermal energy is introduced into the welding wire and the workpiece
Data Source
AI summary
A welding device and a short-circuit welding method uses successive welding cycles having respective arc and short-circuit phases. The method includes: conveying a welding wire from a workpiece, bringing the wire to a final rearward speed in a first rearward conveying phase and then conveying it at that speed until a second rearward conveying phase where the rearward speed is reduced; and conveying the wire toward the workpiece, the welding wire being brought to a final forward speed in a first forward conveying phase and being conveyed at that speed until the beginning of a second forward conveying phase where the forward speed is reduced. The first duration is adapted using a feedforward control and/or feedback control such that the welding wire does not exceed a specified reduced rearward speed in the second rearward conveying phase at the point in time at which the short-circuit is interrupted.