Submerged Arc Welding Control for Reliable Arc Start
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Solution Overview
Problem
Existing submerged arc welding systems require complex parameter adjustments and time-consuming processes for arc start, particularly when switching between different arc start methods, leading to poor operability and inefficiency.
Innovation Solution
A submerged arc welding system with a control unit that automatically adjusts welding parameters by detecting a short circuit, stopping wire feed, and initiating welding current based on a voltage threshold, allowing for a unified control process across various arc start methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding power supply system performs the process of checking the contact state between the tip of the welding wire and the workpiece and subsequently passing a start current, then good starting performance is achieved, but the process takes time and reduces productivity
Solution Approach 1:
The control unit automatically performs preliminary actions by detecting the short circuit state and automatically adjusting welding parameters (current, voltage, wire feed speed) before the welding arc is established. This preliminary automated control eliminates manual parameter adjustment time and ensures optimal starting conditions are met quickly, resolving the contradiction between reliable starting performance and welding productivity
2Reliability
If three parameters (start current, feed speed of the welding wire, and end condition of the start period) are adjusted to achieve good starting performance, then starting performance is improved, but the complexity of parameter adjustment increases
Solution Approach 1:
The control unit automatically detects the short circuit state and self-adjusts the welding parameters (start current, feed speed, and end condition) without requiring manual intervention. The system serves itself by using the voltage sensor to detect contact state and automatically determining when to transition from start current to welding current, eliminating the need for operators to manually adjust multiple parameters while ensuring optimal starting performance
3Adaptability or versatility
If the control at the arc start is switched depending on the arc start method, then different arc start methods can be accommodated, but the operability deteriorates due to the need for switching control modes
Solution Approach 1:
The control unit implements a universal control mechanism that automatically detects the short circuit state regardless of the specific arc start method being used. By monitoring the voltage between the welding wire tip and workpiece, the system universally determines contact state and automatically adjusts parameters for any arc start method (whether inserting wire into molten pool or other methods), eliminating the need for operators to switch control modes while maintaining adaptability to different welding techniques
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
Simplifies parameter setting by eliminating the need to adjust start current and feed speed, ensuring consistent arc start performance regardless of the method, and preventing wire breakage or stick phenomena.
Implementation Method 1
a voltage sensor configured to detect voltage applied between a tip of the welding wire and a workpiece
Implementation Method 2
an arc is generated between the tip of the welding wire and the workpiece to perform welding
Implementation Method 3
a current is passed to generate an arc
Data Source
AI summary
A submerged arc welding system includes a welding power supply, a welding wire feeder, a control unit for the welding power supply and the welding wire feeder, and a voltage sensor to detect voltage between the tip of the welding wire and a workpiece. Under the control of the control unit, the wire feeder feeds the welding wire at an initial feed speed at start of welding. Further, when the tip of the welding wire shorts to the workpiece, the wire feeder stops the feeding of the welding, and the welding power supply starts outputting welding current. Further, when a detection voltage detected by the voltage sensor reaches or exceeds a voltage threshold, the wire feeder starts feeding the welding wire at a welding feed speed for welding.