Submerged Arc Welding Current Control for Short-Circuit Release
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Solution Overview
Problem
Submerged arc welding methods face challenges in maintaining welding quality when a short circuit occurs between the welding wire and the base material, leading to potential welding failures and uneven penetration due to the lack of effective control mechanisms.
Innovation Solution
A submerged arc welding control method that includes providing a short-circuit current with a peak value of 1500 A to 2500 A, controlling the rise rate of the short-circuit current to 400 A/ms to 1500 A/ms, and maintaining the output polarity during the short circuit to promptly release it, followed by alternating polarity switching after the arc is regenerated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If variable feed speed control is used to maintain arc length, then welding quality is improved under normal conditions, but welding quality deteriorates when a short circuit occurs
Solution Approach 1:
The invention dynamically changes the control mode based on welding state. During normal welding, variable feed speed control maintains arc length. When short circuit is detected, the system switches to constant current control with specific parameters (peak current 1500-2500A, rise rate 400-1500A/ms) to quickly release the short circuit, then returns to variable feed speed control. This dynamic adaptation resolves the contradiction by optimizing control for each specific welding state.
Solution Approach 2:
The invention changes control parameters based on welding conditions. Normal welding uses voltage feedback control for arc length maintenance, while short circuit conditions trigger a parameter switch to constant current mode with peak current limited to 1500-2500A and rise rate controlled at 400-1500A/ms. This parameter transformation enables the system to handle both normal and abnormal conditions effectively.
2Productivity
If short circuit occurs between welding wire and base material, then welding process continues, but welding quality deteriorates due to welding failure and uneven penetration
Solution Approach 1:
The invention converts the harmful short circuit condition into a beneficial control opportunity. When short circuit occurs, the system activates constant current control with peak current 1500-2500A and rise rate 400-1500A/ms, which quickly melts the wire end and releases the short circuit. This transforms a welding defect into a controlled process event that actually helps clear obstacles and maintain productivity.
Solution Approach 2:
The invention applies preliminary control actions to prevent short circuit damage. By detecting short circuit conditions and immediately applying controlled constant current with peak 1500-2500A, the system prevents the short circuit from causing welding failures and uneven penetration, thereby protecting welding quality while maintaining process continuity.
3Loss of time
If constant current control is used during short circuit, then short circuit is released quickly, but control complexity increases
Solution Approach 1:
The invention uses periodic monitoring and conditional switching. The control system continuously monitors welding voltage and current, periodically detects short circuit conditions, and switches control modes only when necessary. This periodic action approach keeps the system simple during normal operation while enabling quick response when needed, reducing both time loss and control complexity.
Solution Approach 2:
The invention employs feedback control to manage complexity. By monitoring welding voltage and current and using this feedback to detect short circuit conditions, the system automatically switches between control modes without operator intervention. This feedback mechanism simplifies the overall control structure by using simple voltage/current measurements to trigger complex control actions only when necessary.
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
The method effectively shortens the short-circuit period to approximately 200 ms or less, preventing welding quality deterioration by promptly releasing the short circuit and ensuring stable arc regeneration.
Implementation Method 1
providing a welding voltage and a welding current between the welding wire and a base material to generate an arc
Data Source
Figure 1
Figure 2(A)~2(D)
Figure 3(A)~3(D)
AI summary
A submerged arc welding control method is provided for performing welding by feeding a welding wire and providing a welding voltage and a welding current between the welding wire and a base material to generate an arc. The submerged arc welding control method includes: providing a short-circuit current when a short circuit between the welding wire and the base material is determined; controlling a peak value of the short-circuit current to be in a range of 1500 A to 2500 A.