Submerged Arc Welding Start Control Using Voltage Thresholds
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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 controls a welding power supply and wire feeder to automatically adjust parameters based on detected voltage thresholds, allowing for a unified start control process across various arc start methods, including stopping wire feed upon short-circuit detection and restarting at a set welding speed when a voltage threshold is reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding power supply system checks the contact state between the welding wire tip and workpiece before passing start current, then the arc start reliability is improved, but the welding start time is increased
Solution Approach 1:
The patent extracts the contact state checking step from the welding start process. By detecting voltage to determine short-circuit state directly, the system removes the time-consuming manual or separate sensor-based contact checking step, achieving both fast response and reliable arc start without the need for preliminary contact verification
Solution Approach 2:
The patent replaces mechanical contact state checking with electrical voltage detection. Instead of using mechanical sensors or manual verification to check if the wire tip contacts the workpiece, the system uses voltage sensing to detect short-circuit state, enabling faster and more reliable detection without mechanical intervention
2Adaptability or versatility
If the control system switches control methods depending on the arc start method, then the adaptability to different welding processes is improved, but the operability is deteriorated
Solution Approach 1:
The patent creates a universal control method that works across different arc start methods (contact start, non-contact start, multi-electrode welding). By using voltage detection to identify short-circuit state as the unified control basis, the system eliminates the need to switch between different control algorithms, providing consistent operability while maintaining adaptability to various welding processes
3Reliability
If three parameters (start current, feed speed, end condition) are adjusted for good starting performance, then the arc start quality is improved, but the parameter adjustment complexity is increased
Solution Approach 1:
The patent changes the control parameter from multiple parameters (start current, feed speed, end condition) to a single voltage threshold parameter. By detecting voltage to determine short-circuit state and using this as the sole control basis for arc start, the system maintains high arc start quality while dramatically reducing parameter adjustment complexity to just one threshold value
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
Facilitates easy parameter adjustment and ensures consistent arc start performance regardless of the arc start method, preventing wire breakage and achieving a stable arc length, thus improving operational efficiency and versatility.
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
granular flux is applied over a workpiece, a welding wire is then fed into the flux
Data Source
Figure 1A~1B
Figure 2
Figure 3
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.