Synergic Welding Power Control for Variable Thickness Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding power supplies lack the ability to synergically adjust output power during welding, particularly when dealing with workpieces of varying thickness and geometry, leading to issues such as lack of fusion or burn-through.
Innovation Solution
The development of a welding-type power supply system that allows operators to synergically control output power by simultaneously adjusting voltage and wire feed speed using a manually accessible control on the torch, enabling real-time adjustments to match changing work conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional welding power supplies use fixed output power settings, then the device complexity is reduced and ease of operation is improved, but the adaptability to varying workpiece thickness and geometry deteriorates
Solution Approach 1:
The system changes welding parameters (voltage and wire feed speed) in a coordinated manner based on workpiece thickness. The controller automatically adjusts these parameters according to pre-stored synergistic data, enabling adaptation to different workpiece conditions without requiring complex manual intervention or increasing overall device complexity.
2Ease of operation
If conventional welding power supplies allow independent adjustment of voltage and wire feed speed, then the adaptability to different welding conditions is improved, but the ease of operation deteriorates due to the need for multiple separate controls
Solution Approach 1:
The system merges the control of voltage and wire feed speed into a single unified interface. When the operator adjusts one parameter, the controller automatically coordinates the other parameter based on pre-stored synergistic relationships, maintaining adaptability while significantly improving ease of operation.
Solution Approach 2:
The system incorporates feedback mechanisms where the controller continuously monitors the welding parameters and automatically adjusts them based on pre-stored synergistic data. This feedback loop ensures that voltage and wire feed speed remain coordinated, maintaining optimal welding conditions without requiring complex manual adjustments.
3Manufacturing precision
If conventional welding power supplies use preselected voltage and wire feed speed, then the device complexity is reduced, but the manufacturing precision of weld quality deteriorates when dealing with varying workpiece geometry
Solution Approach 1:
The system performs preliminary actions by pre-storing synergistic voltage and wire feed speed data for different workpiece thicknesses and welding conditions. This pre-programmed data allows the controller to automatically select optimal parameter combinations during welding, ensuring consistent weld quality without increasing device complexity.
Solution Approach 2:
The system dynamically changes welding parameters (voltage and wire feed speed) based on the specific workpiece conditions. By coordinating these parameter changes according to pre-stored synergistic relationships, the system maintains high manufacturing precision for weld quality while avoiding the need for complex real-time calculations or multiple independent controls.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Methods and apparatus to synergically control a welding-type output during a welding-type operation are disclosed. An example welding-type power supply includes a power conversion circuit configured to convert input power to welding-type power and to output the welding-type power to a welding-type torch; a communication circuit configured to receive a control signal from a remote control device during a welding-type operation; and a control circuit configured to synergically control a voltage of the welding-type power and a wire feed speed based on the control signal.