Stud Welding Arc Deflection for Uniform End-Face Melting
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Solution Overview
Problem
Existing stud welding methods result in uneven arc distribution and melting of the stud and workpiece, leading to suboptimal welded joints, and often require specialized stud shapes or configurations.
Innovation Solution
A stud welding method and device that synchronously and oppositely control the current through a coil generating a magnetic field to deflect the arc, ensuring optimal arc positioning and uniform melting of the stud and workpiece, without requiring special stud shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a magnetic field is applied to deflect the arc to improve melting uniformity, then the quality of the welded joint is improved, but the device complexity increases due to the additional coil and control system
Solution Approach 1:
The patent applies periodic pulsing of both the welding current and the coil current to achieve uniform arc distribution. The welding current is pulsed at a fundamental frequency while the coil current is pulsed at a higher frequency (multiples of the fundamental), creating periodic magnetic field deflections that sweep the arc across the stud surface uniformly, ensuring even melting without requiring complex continuous control systems
Solution Approach 2:
The patent controls the parameters of the coil current (amplitude, frequency, phase) relative to the welding current to optimize arc deflection. By adjusting these parameters, the magnetic field strength and direction are dynamically changed to achieve optimal arc distribution and melting uniformity while managing the complexity of the control system
2Manufacturing precision
If the arc is deflected using a transverse magnetic field to achieve even melting, then the welded joint quality improves, but the process becomes more difficult to control
Solution Approach 1:
The patent employs feedback control where the coil current is adjusted based on the state of the welding process. The control system monitors the welding current and automatically adjusts the coil current parameters (amplitude, frequency, phase) to maintain optimal arc deflection and positioning, making the process easier to operate while achieving uniform melting
Solution Approach 2:
By using periodic pulsing of the coil current synchronized with the welding current, the arc is automatically swept across the stud surface in a controlled manner. This periodic action simplifies control by using rhythmic, predictable patterns rather than requiring continuous complex adjustments, achieving even melting while maintaining ease of operation
3Ease of manufacture
If conventional stud welding is performed without arc deflection, then the process is simple and inexpensive, but the arc distribution is uneven resulting in poor welded joint quality
Solution Approach 1:
The patent uses periodic pulsing of the coil current at multiples of the welding current frequency to create a cost-effective control scheme. This approach achieves uniform arc distribution through simple rhythmic deflection patterns, maintaining process simplicity and low cost while significantly improving arc distribution uniformity and welded joint quality compared to conventional methods
Solution Approach 2:
The patent achieves improved arc distribution by dynamically changing the coil current parameters (amplitude, frequency, phase) in a controlled manner. This parameter control enables uniform melting and high-quality welds while keeping the system relatively simple and cost-effective, avoiding the need for complex continuous adjustment mechanisms
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
Achieves a uniform and high-quality welded joint by ensuring even arc distribution and melting, while allowing for the use of standard studs and simplifying the welding process.
Implementation Method 1
a magnetic field which is generated by a coil through which a current flows
Implementation Method 2
the arc is deflected with the aid of a magnetic field
Implementation Method 3
an arc is generated with the aid of a pulsed welding current between the surface of the stud facing the workpiece and the workpiece
Implementation Method 4
an arc is ignited between the end face of the stud facing the workpiece and the workpiece, thereby locally melting both the stud and the workpiece
Data Source
AI summary
A stud welding process and a stud welding device for welding a stud to a workpiece are provided, wherein an arc (LB) is generated between the surface of the stud that faces the workpiece and the workpiece by using a pulsed welding current (Is), and the arc (LB) is deflected by a magnetic field which is generated by a coil through which a current (IA) flows. The current (IA) through the coil for generating the magnetic field for deflecting the arc (LB) is activated synchronously and in anti-phase with the welding current (Is) by a current (IA) always being applied to the coil when the welding current (Is) is at a minimum, and the coil being switched off or the current (IA) through the coil being reduced to a minimum when the welding current (Is) is at a maximum.