Thermal Cycle Control for Strip Butt Welds
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Solution Overview
Problem
Current methods for controlling the thermal cycle of butt welds in steel strip processing facilities are inadequate, leading to poor quality welds due to manual adjustment of welding parameters based on general material characteristics, resulting in potential embrittlement and increased production costs.
Innovation Solution
A method and device for automatically controlling the thermal cycle of butt welds by measuring and adjusting welding energy, speed, and heat treatment parameters in real-time, using a database to classify strip materials and determine optimal thermal parameters based on their specific characteristics, ensuring precise regulation of the metallurgical structure during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of welding parameters based on general material characteristics is used, then the control method is simple, but the weld quality deteriorates due to embrittlement
Solution Approach 1:
The system measures the actual thermal cycle parameters during welding and compares them with reference values, then automatically adjusts welding parameters based on this feedback to maintain optimal weld quality and prevent embrittlement
Solution Approach 2:
The patent replaces manual mechanical adjustment of welding parameters with an automated control system that uses sensors, processors, and actuators to dynamically adjust parameters based on real-time measurements and reference data
2Productivity
If welding parameters are not precisely controlled, then the welding process is faster and simpler, but metallurgical alterations occur in the heat-affected zone
Solution Approach 1:
The system pre-establishes reference thermal cycle parameters for different steel grades and uses these references to guide real-time welding parameter selection, ensuring optimal metallurgical quality before welding begins
Solution Approach 2:
The system dynamically adjusts welding parameters such as heat input, welding speed, and thermal cycle characteristics based on measured values and reference data to prevent metallurgical alterations while maintaining productivity
3Reliability
If post-weld annealing is used to treat embrittlement, then weld quality can be restored, but production time increases
Solution Approach 1:
The system performs preheating before welding based on reference thermal cycle parameters to prevent embrittlement from occurring in the first place, eliminating the need for subsequent annealing operations and reducing total production time
Solution Approach 2:
The system uses controlled thermal cycles during welding to achieve the beneficial effects previously requiring separate post-weld annealing, thereby preventing harm (embrittlement) while maintaining productivity
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 ensures high-quality welds by accurately adjusting thermal parameters in real-time, reducing the risk of embrittlement and production losses, while favoring preheating over post-weld annealing, thus optimizing the welding process and minimizing costs.
Implementation Method 1
welding device proper, two pairs of clamping jaws intended to immobilize the strip ends during their joint by welding
Implementation Method 2
guarantee a total junction by fusion of the two ends of the strips to be welded
Implementation Method 3
heat treatment methods for the weld have been developed by those skilled in the art and are implemented by heat treatment devices capable of heating the strip ends or said weld, in particular by electromagnetic induction
Implementation Method 4
the annealing process after welding, the aim of which is to metallurgically restore an acceptable ductility
Data Source
Figure 1~2
Figure 3a~3d
Figure 4
AI summary
The present invention proposes a method and a device (C1) for controlling a thermal cycle of a weld to join one end of a first strip to another end of a second strip, suited to a joining machine (M1) of a strip treatment plant, said control device (C1) comprising: - connection means (C15) intended to connect said control device (C1) to a central automation system (A1) of said strip treatment plant and to said joining machine (M1) respectively, so as respectively to allow an exchange of at least one strip data item and an exchange of at least one operating data item; - a computer (C11) capable of computing, from said strip and operating data items, at least one thermal parameter of said weld; - weld control and characterization means (C14) capable of controlling said welding as a function of said thermal parameter.