Squeezing Detection Control for Consumable Electrode Arc Welding
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Solution Overview
Problem
Existing consumable electrode arc welding methods fail to adequately reduce sputtering during short circuiting periods, leading to suboptimal welding quality due to inappropriate setting of squeezing detection sensitivity for both electrode positive and negative polarities.
Innovation Solution
A squeezing detection control method that alternates the welding power supply output between electrode positive and negative polarities, with distinct squeezing detection reference values set for each polarity to accurately detect and control the squeezing phenomenon, thereby reducing sputtering and enhancing welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single squeezing detection reference value is used for both electrode positive and negative polarities, then the control system is simple, but the squeezing detection accuracy is insufficient leading to inadequate sputtering reduction
Solution Approach 1:
The patent applies local quality by setting different squeezing detection reference values for electrode positive polarity and electrode negative polarity. This allows the control system to adapt to the different electrical characteristics of each polarity, improving squeezing detection accuracy and sputtering reduction effectiveness without requiring an overly complex control architecture.
2Object-generated harmful factors
If the welding current is rapidly decreased upon detecting squeezing, then sputtering is reduced, but the welding process stability is affected
Solution Approach 1:
The patent employs periodic action by alternating the welding power supply output between electrode positive and negative polarities. This periodic polarity switching, combined with rapid current decrease upon squeezing detection, effectively reduces sputtering while maintaining welding process stability through the cyclic nature of the operation.
3Reliability
If distinct squeezing detection reference values are set for each polarity, then squeezing detection control is stabilized and sputtering is significantly reduced, but the device complexity increases
Solution Approach 1:
The patent applies parameter changes by setting different squeezing detection reference values for electrode positive and negative polarities. This parameter differentiation stabilizes squeezing detection control and significantly reduces sputtering by accounting for the distinct electrical characteristics of each polarity, while the complexity increase is managed through systematic parameter management.
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 squeezing detection control, significantly reduces sputtering occurrence, and ensures high-quality welding by setting appropriate sensitivity values for each polarity, improving the overall welding process.
Implementation Method 1
squeezing 1b occurs in the upper portion of the droplet 1a due to the electromagnetic pinching force resulting from the welding current Iw passing through the droplet 1a
Implementation Method 2
the conduction path of the welding current Iw becomes narrow at the squeezed portion, so that the resistance of the squeezed portion increases. The resistance increases as the squeezed portion becomes narrower with the progress of the squeezing. Hence by detecting a change in the resistance between the welding wire 1 and base material 2 during the short circuit period Ts, the occurrence and progress of the squeezing phenomenon can be detected.
Data Source
AI summary
A squeezing detection control method is provided for consumable electrode arc welding. The method includes a step of detecting a droplet squeezing phenomenon by checking that a change in a voltage or resistance between the consumable electrode and base material reaches a squeezing detection reference value, and a step of executing output control for rapidly decreasing a welding current passing through a short-circuited load when the squeezing phenomenon is detected, so that arc re-striking occurs in a state of low current. The squeezing detection reference value is set to a first value during the electrode positive polarity, and set to a second value during the electrode negative polarity. The second value is different from the absolute value of the first value, and each of the first and second values is set such that the resultant welding state is satisfactory.