Submerged Arc Welding Current Control for Short-Circuit Stability
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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 in the range of 1500 A to 2500 A, controlling the rise rate of the short-circuit current between 400 A/ms to 1500 A/ms, and maintaining the output polarity during the short circuit to prevent polarity switching, followed by switching the polarity after the short circuit is released.
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 welding power supply dynamically switches between constant voltage mode (for normal arc length control) and constant current mode (for short circuit protection). This dynamic characteristic change allows the system to adapt to different welding states, maintaining welding quality during normal operation while preventing deterioration when short circuits occur
Solution Approach 2:
The control system continuously monitors welding voltage and current to detect short circuit conditions. When a short circuit is detected, the system provides feedback to switch to constant current mode with limited peak current, preventing the harmful effects of uncontrolled short circuit current while maintaining welding quality
2Stability of the object's composition
If constant current characteristics are used to control arc length, then arc length stability is improved, but the system becomes less responsive to rapid welding state changes
Solution Approach 1:
The welding power supply employs dynamic characteristic switching, transitioning from constant voltage mode (faster response) to constant current mode (better stability) based on the welding state. This allows the system to maintain arc length stability during normal operation while responding rapidly to short circuit conditions
3Device complexity
If no short circuit control is implemented, then device complexity is reduced, but welding quality deteriorates due to uncontrolled short circuits
Solution Approach 1:
The control system monitors welding parameters (voltage and current) and dynamically adjusts the power supply characteristics based on detected conditions. When a short circuit is detected through parameter changes, the system switches to constant current mode with limited peak current, providing effective short circuit control without requiring complex additional hardware
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 method effectively shortens the short-circuit period to approximately 200 ms or less, thereby preventing deterioration of welding quality 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
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.