Stepper Motor Drawn Arc Welding for 150-Foot Single-Phase Operation
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Solution Overview
Problem
Conventional drawn arc welding systems require three-phase power and non-stepper motor weld guns to achieve long welding distances, limiting their operational flexibility and weld quality.
Innovation Solution
A drawn arc welding system that includes a power inverter module capable of receiving single-phase power, a stepper motor weld gun, and a control module to monitor and control welding parameters, enabling welding distances of up to 150 feet without significant reduction in weld quality, using a power inverter module with rectifiers, capacitors, and transistors to output welding power efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional drawn arc welding systems use three-phase power and non-stepper motor weld guns, then welding distance can be achieved, but operational flexibility and weld quality are limited
Solution Approach 1:
The patent changes the power input parameter from three-phase to single-phase, enabling the system to operate in locations without three-phase power. The power inverter module converts single-phase power to the required welding power parameters, maintaining weld quality while improving operational flexibility and adaptability to different site conditions.
2Length of moving object
If welding distance is extended to 150 feet, then operational reach is improved, but weld quality may be reduced
Solution Approach 1:
The patent replaces traditional mechanical weld gun actuation with a stepper motor system that provides precise control of the welding process parameters even at extended distances. The stepper motor enables accurate positioning and consistent welding performance at 150 feet, eliminating the quality degradation that would normally occur with extended cable lengths.
Solution Approach 2:
The control module monitors welding parameters and provides feedback to maintain consistent weld quality despite the extended 150-foot distance. This feedback mechanism ensures that welding parameters remain within acceptable ranges throughout the extended cable length, preventing quality degradation.
3Adaptability or versatility
If single-phase power is used instead of three-phase power, then adaptability to locations without three-phase power is improved, but power delivery capability may be reduced
Solution Approach 1:
The power inverter module converts single-phase power to the required welding power parameters, adjusting voltage, current, and frequency to match welding requirements. This parameter transformation enables single-phase power to deliver sufficient power for welding applications, matching the capability of three-phase systems while providing greater adaptability to site conditions.
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
Enables superior weld control and quality at extended distances using single-phase power, allowing operation in locations without three-phase power and achieving 6 welds per minute at 150 feet with improved precision and efficiency.
Implementation Method 1
a power inverter module including a rectifier and a capacitor
Implementation Method 2
a power inverter module including a rectifier and a capacitor
Implementation Method 3
Drawn arc welding typically uses a welding current, supplied by a power supply, to weld a stud to a base material
Data Source
AI summary
A drawn arc welding system includes a weld gun having a stepper motor, a power inverter module configured to receive a single-phase power input and output welding power to the weld gun, and a control module having a stepper motor driver, a user interface, and a controller in communication with the stepper motor driver, the user interface, and the power inverter module. The controller is configured to receive a current for the welding power from the user interface, and instruct the power inverter module to output the current to the weld gun.