Submerged Arc Welding Control for Stable Cold Wire Melting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Submerged arc welding processes using cold wires often experience instability and weld defects due to uneven melting of cold wires, leading to increased welding process instability and inclusions of unmelted wire material in the weld metal.
Innovation Solution
A method and system for submerged arc welding that continuously measures and adapts active welding parameters to adjust the cold wire feed speed in real-time, ensuring stable welding conditions and improved weld quality by linking the cold wire feed speed to hot wire parameters such as welding current, arc voltage, and feed speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cold wire feed speed is increased to improve deposition rate, then productivity increases, but welding process stability deteriorates and unmelted wire material is generated
Solution Approach 1:
The cold wire feed speed is made dynamically adjustable based on real-time welding conditions. The control system continuously monitors welding parameters (current, voltage, speed) and automatically adjusts the cold wire feed speed to optimize both deposition rate and melting quality, preventing unmelted material while maintaining high productivity
Solution Approach 2:
A feedback control mechanism is implemented where the actual welding parameters are measured and used to regulate the cold wire feed speed. The control system receives feedback on welding current, voltage, and speed, and adjusts the cold wire feed accordingly to ensure proper melting and process stability
2Reliability
If cold wire feed speed is decreased to improve melting quality, then welding process stability improves, but productivity decreases
Solution Approach 1:
The system dynamically adjusts cold wire feed speed based on real-time welding conditions rather than using a fixed speed. This allows the feed speed to be optimized for each specific welding scenario, achieving both good melting quality and high productivity
Solution Approach 2:
The control system changes the cold wire feed speed parameter in response to variations in welding current, voltage, and speed. By adjusting this parameter dynamically, the system maintains optimal melting conditions while maximizing deposition rate
3Productivity
If multiple hot wires are used to increase deposition rate, then productivity increases, but device complexity increases
Solution Approach 1:
The patent combines multiple hot wires and cold wires into a single integrated welding system with unified control. This merging approach enables increased deposition rate through multiple electrodes while the centralized control system manages the complexity, coordinating all wires to work together efficiently
4Use of energy by moving object
If cold wire is used to increase deposition rate without increasing heat input, then energy efficiency improves, but control precision deteriorates
Solution Approach 1:
A feedback control system is implemented that continuously monitors welding parameters and adjusts cold wire feed speed accordingly. This feedback mechanism provides the precision needed for accurate feed speed control while maintaining energy efficiency, as the system responds to actual welding conditions rather than relying on open-loop control
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 process and enhances weld quality by maintaining optimal cold wire feed rates in response to changing welding conditions, preventing defects and ensuring consistent deposition rates without increasing heat input.
Implementation Method 1
The weld current forms an arc between the consumable electrode and the work piece to create a weld puddle on the work piece
Implementation Method 2
A cold wire is continuously fed towards a molten weld puddle in close proximity to one or more hot wires, where the cold wire is melted by heat generated by said hot wires
Implementation Method 3
The flux melts in part during the process, thus creating a protecting layer of slag on the weld puddle
Data Source
AI summary
A submerged arc welding apparatus includes a first wire feeder feeding a first hot wire towards a work piece; a first contact tube transferring current to the first hot wire for arc generation to create a weld puddle; a second wire feeder feeding a cold wire at a variable feed speed towards the weld puddle; one or more sensors configured to continuously measure, during a welding phase, at least a first active welding parameter related to at least the first hot wire; and a control unit. The control unit is configured to determine different target values for the variable feed speed of the cold wire based on different values of the at least a first active welding parameter such that a different target value for the variable feed speed of the cold wire is determined according to a different value of the at least a first active welding parameter.