Waveform Compensation for Welding Voltage Errors
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Solution Overview
Problem
Welding systems face quality issues due to voltage errors caused by the inductance and resistance of secondary components like weld cabling, which are exacerbated by the high current levels in welding processes, and existing solutions often require additional cabling for voltage sensing, complicating the setup.
Innovation Solution
A method and system that analyze weld waveforms to determine compensation for inductance errors in secondary components, adjusting the weld voltage control to minimize errors without the need for additional voltage sensing leads, by comparing stud voltage and current ramp percentages to estimate and adjust inductance compensation values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If voltage sensing leads are added to sense voltage at the weld without being affected by voltage error, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the voltage sensing function from the physical voltage sensing lead and implements it through waveform analysis of existing signals. By analyzing the relationship between stud voltage waveform and current waveform to calculate inductance effects, the system obtains accurate voltage measurements without requiring additional sensing leads, thus eliminating the added complexity while maintaining measurement precision.
2Manufacturing precision
If additional voltage sensing leads are installed, then weld quality control is improved, but ease of operation deteriorates
Solution Approach 1:
The system uses the existing voltage and current signals already present in the welding circuit to perform self-diagnosis and compensation. By analyzing the waveform characteristics and calculating inductance effects from these existing signals, the system achieves weld quality control without requiring additional sensing leads or complex setup procedures, thereby maintaining ease of operation while improving manufacturing precision.
3Manufacturing precision
If waveform analysis and inductance compensation are implemented, then weld quality is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback control by continuously analyzing the relationship between stud voltage waveform and current waveform, calculating the inductance effect, and using this information to compensate for voltage errors. This feedback mechanism improves weld quality by dynamically adjusting for inductance effects without requiring complex additional hardware, as the compensation is achieved through signal processing of existing measurements.
Data Source
AI summary
A method includes receiving data corresponding to a voltage level over time and a current level over time. The method also includes determining a first ratio corresponding to a voltage ramp percent or a voltage falling edge percent with respect to a peak in the voltage level and determining a second ratio corresponding to a current ramp ratio or a current falling edge ratio with respect to a peak in the current level. The method further includes determining, based on a comparison between the first ratio and the second ratio, whether to increment, decrement, or maintain an inductance compensation estimation value corresponding to an estimated inductance present in one or more secondary components associated with the welding operation.