Tandem Arc Welding Head With Overlapping Arcs for Cold Wire Melting

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Solution Overview

Problem

Tandem welding technologies face challenges in maintaining high deposition rates while ensuring welding quality, as electrodes separated too far can result in incomplete fusion and variable deposition rates due to premature solidification of the weld puddle.

Innovation Solution

An electric arc welding head with integrated first and second contact devices for separate electrodes and a third duct for a cold wire, allowing for controlled electrode positioning and overlapping arc regions to stabilize the melting process, thereby enhancing deposition rates and weld quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electrodes are positioned at a distance from each other in the welding direction, then each electrode can perform different tasks (leading electrode for penetration, trailing electrode for bead appearance), but the weld puddle generated by the first electrode may solidify before the second electrode reaches it, resulting in incomplete fusion and variable deposition rates

Engineering Contradiction:

Improveability to assign different tasks to leading and trailing electrodesVSAvoidweld quality consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent combines multiple electrodes and a cold wire feed system into a single integrated welding head assembly. This merging allows the electrodes to be positioned close to each other while maintaining independent control, ensuring they operate in a common weld puddle without premature solidification, thus achieving both task differentiation and reliable fusion.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces a cold wire feed system as an intermediary element between the two electrodes. The cold wire is fed into the weld puddle and melts due to heat from the electrodes, providing additional filler material that ensures complete fusion and stabilizes the deposition rate, preventing the weld puddle from solidifying too early.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If electrodes are positioned side by side in the transverse direction, then surface welding and wide joints can be achieved, but penetration is reduced and weld quality may be compromised

Engineering Contradiction:

Improveweld widthVSAvoidweld penetration

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The patent transitions from a single-dimension (transverse) electrode arrangement to a multi-dimensional configuration by positioning electrodes in the welding direction (longitudinal dimension) while maintaining close proximity. This dimensional change allows the electrodes to work together to achieve both adequate penetration through their combined thermal input and controlled weld width.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If a cold wire is fed into the weld puddle, then deposition rate can be increased by up to 50%, but the melting process must be precisely controlled to prevent wire detachment or penetration into the puddle bottom

Engineering Contradiction:

Improvedeposition rateVSAvoidcold wire melting control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system that monitors the welding process parameters and adjusts the cold wire feed rate and electrode positions accordingly. This feedback mechanism ensures the cold wire melts at the optimal rate, preventing both detachment and excessive penetration into the weld puddle bottom, thus maintaining high deposition rates with precise control.

Inventive Principle:

Principle #23Feedback

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 solution achieves a stable welding process with up to 50% increase in deposition rate, reducing variations and ensuring consistent weld quality by maintaining a controlled melting of the cold wire within the overlapping arc region.

Implementation Method 1

an arc electric welding head comprising a first contact device housing a first duct for feeding a first electrode and providing electrical contact between a first power source and said first electrode

Methodology Applied

Scientific EffectElectric arc: Electric Arc

Implementation Method 2

the first and second ducts being arranged at a distance which allows for arcs between said first and second electrodes and a work piece to be welded will have an overlapping region

Methodology Applied

Scientific EffectArc heating: Electric Arc

Data Source

PatentUS10994362B2Tandem arc welding head and a welding arrangement for overlapping arcs to a cold wire electrode

Publication Date: 2021.05.04 ESAB AB

AI summary

An arc electric welding head comprising a first contact device housing a first duct for feeding a first electrode and providing electrical contact between a first power source and said first electrode, a second contact device housing a second duct for feeding a second electrode and providing electrical contact between a second power source and said second electrode, said first and second contact devices being electrically insulated from each other, said first and second ducts being parallel.