Weaving-Based Welding State Detection Without Threshold Retuning

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Solution Overview

Problem

Existing methods for determining the welding state in arc welding require changing threshold values and detection value ranges when welding conditions change, such as the object being welded, gas, or set current, which is inefficient and inaccurate.

Innovation Solution

A welding state determination system that uses a weaving operation to cyclically oscillate a welding torch, acquiring characteristic amounts related to physical quantities that change with the weaving cycle, calculating a degree of abnormality based on these values and their past averages and standard deviations, and determining the welding state accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If threshold values and detection value ranges are changed according to welding conditions, then welding state determination accuracy is improved, but system complexity and operation difficulty increase

Engineering Contradiction:

Improvewelding state determination accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system automatically adapts to different welding conditions by using the weaving operation characteristics themselves to generate determination criteria, eliminating the need for manual threshold adjustments. The system serves itself by deriving its own parameters from the process being monitored.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention changes the approach from adjusting fixed threshold parameters to using dynamic parameters derived from the weaving operation. By monitoring how physical quantities change during the oscillation cycle and comparing them to historical data, the system adapts to different welding conditions without requiring manual parameter changes.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If threshold values and detection value ranges are changed according to welding conditions, then welding state determination accuracy is improved, but ease of operation deteriorates

Engineering Contradiction:

Improvewelding state determination accuracyVSAvoidoperation difficulty

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If setting values are changed when welding conditions change, then adaptation to different conditions is improved, but loss of time for adjustment increases

Engineering Contradiction:

Improveadaptation to welding conditionsVSAvoidadjustment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system performs preliminary analysis of the weaving operation characteristics to establish determination criteria before actual welding state evaluation begins. By pre-processing the oscillation data and historical values, the system is ready to immediately assess welding states without adjustment delays.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If fixed threshold values are used, then ease of operation is improved, but measurement precision deteriorates

Engineering Contradiction:

Improveoperation simplicityVSAvoidwelding state determination accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12214450B2Welding state determination system and welding state determination method

Publication Date: 2025.02.04 KOBE STEEL LTD

AI summary

This welding state determination system acquires, for each weaving cycle, a characteristic amount that pertains to a physical quantity that changes according to the cycle of a weaving operation. A degree of abnormality is calculated based on an observation value that is the characteristic amount acquired in one cycle, and the average and standard deviation of a plurality of past values that are the characteristic amounts acquired prior to the one cycle. A welding state is determined based on the calculated degree of abnormality.