Tandem Welding Head Horizontal Control via Arc Signal Difference
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Solution Overview
Problem
Tandem welding heads with two independent wire feeds face challenges in achieving precise positioning and high welding speeds due to the need for complex control methods and the limitations of existing seam tracking techniques, particularly when the welding head is arranged at angles other than 0° to the seam joint.
Innovation Solution
A method for determining a horizontal control signal by measuring the difference in welding currents or resistances between two burner units, allowing for independent control and synchronization of welding cycles, which enables precise positioning and high-speed welding without the need for pendulum movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single-wire welding heads are used, then device complexity is low, but welding speed and deposition rate are limited
Solution Approach 1:
The welding system is segmented into two independent torch units, each with its own wire feed and power source. This segmentation allows each torch to operate independently at high speed while maintaining simplified individual structures, resolving the contradiction between high welding speed and device complexity
Solution Approach 2:
Two independent welding systems are merged into a single tandem welding head that operates as one coordinated unit. The merging of two high-speed welding capabilities achieves superior productivity while the integrated control system manages the complexity, allowing both torches to contribute to the weld seam simultaneously
2Productivity
If tandem welding head is used with two independent power sources, then welding speed and deposition rate increase, but control complexity increases
Solution Approach 1:
The control system continuously monitors welding parameters from both power sources and adjusts them in real-time to maintain optimal welding conditions. This feedback mechanism coordinates the two independent power sources, managing control complexity while maximizing deposition rate and productivity
Solution Approach 2:
The control system dynamically adjusts the operating parameters of both torch units based on real-time welding conditions, allowing flexible coordination of the two power sources. This dynamic control enables high deposition rates while adapting to varying workpiece conditions, managing the complexity through intelligent real-time adjustment
3Manufacturing precision
If existing seam tracking techniques are used, then positioning can be achieved, but welding speed is limited due to complex control methods
Solution Approach 1:
The control system employs periodic measurement cycles with defined stable time intervals for determining measurement signals from both torch units. This periodic approach allows precise positioning to be achieved during stable intervals while maintaining high overall welding speed, resolving the contradiction between positioning precision and productivity
4Measurement precision
If measurement signals are determined during stable time intervals in different welding cycles, then positioning precision improves, but control coordination becomes more complex
Solution Approach 1:
The control system is configured in advance to coordinate the welding cycles of both torch units, pre-defining the stable time intervals for measurement signal determination. This preliminary coordination of measurement timing from both torches improves burner distance measurement precision while managing cycle coordination complexity through pre-planned synchronization
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 approach allows for high-precision weld seams at very high welding speeds, expanding the application and configuration options for tandem welding heads by eliminating the need for pendulum movements and enabling operation with different welding processes.
Implementation Method 1
a first arc being maintained from the first torch unit to the seam joint during a first welding cycle, a second arc being maintained from the second torch unit to the seam joint during a second welding cycle
Data Source
Figure 1
Figure 2a~2c
Figure 3a~4
AI summary
Method for determining a horizontal control signal (1) for a tandem welding head (2) which is guided along a weld joint (3) and has two torch units (4, 4') arranged side by side. Each torch unit (4, 4') has a feed for a welding wire (5). The first torch unit (4) is guided with a first torch distance (7) over a first joint surface (8) on a first side of a weld joint center (9) of the weld joint (3), and the second torch unit (4') is guided with a second torch distance (7') over a second joint surface (8') on a second side of the weld joint center (9). A first arc (10) is maintained continuously or at least intermittently during a first welding cycle from the first torch unit (4) to the weld joint (3), and a second arc (10') is maintained continuously or at least intermittently during a second welding cycle from the second torch unit (4') to the weld joint (3).For the first burner unit (4), a first measurement signal (12) representative of the first burner spacing (7) is determined, and for the second burner unit (4'), a second measurement signal (12') representative of the second burner spacing (7') is determined. Determining the horizontal control signal (1) involves calculating the difference between the first measurement signal (12) and the second measurement signal (12').