Inclined-Surface Weld Bead Mapping to Prevent Dripping and Humping
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Solution Overview
Problem
The formation of weld beads on inclined surfaces is prone to dripping due to gravity, and increasing the torch's traveling speed to prevent dripping can lead to humping, which breaks the weld bead.
Innovation Solution
A method and apparatus that use pre-calculated maps to determine optimal bead heights and widths based on base-surface and track inclination angles, controlling the torch's movement and heat input to prevent dripping and humping, by selecting bead parameters from stored maps that account for gravitational influence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the torch traveling speed is increased to prevent dripping on inclined surfaces, then the productivity is improved, but the manufacturing precision deteriorates due to humping and weld bead breakage
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting welding parameters (traveling speed, heat input, bead height, bead width) based on the inclination angle. Pre-calculated maps store optimal parameter combinations for different angles, allowing the system to select appropriate parameters that prevent both dripping and humping while maintaining productivity.
2Manufacturing precision
If the torch traveling speed is reduced to prevent humping, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The patent uses preliminary action by pre-calculating and storing optimal welding parameters in maps before actual welding begins. The system determines the inclination angle in advance and selects the corresponding optimal parameters from the pre-prepared maps, enabling high-speed welding without humping by having the correct parameters ready beforehand.
3Device complexity
If conventional welding parameters are used on inclined surfaces, then the device complexity is minimized, but the reliability deteriorates due to dripping and humping
Solution Approach 1:
The patent implements feedback by using the detected inclination angle to automatically select appropriate welding parameters from pre-calculated maps. The system continuously monitors the inclination angle and adjusts parameters accordingly, creating a closed-loop control system that ensures reliable weld bead formation without requiring complex real-time calculations or interventions.
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
Efficiently forms weld beads without issues like dripping or humping, ensuring high-quality built-up objects with reduced production time by selecting appropriate bead dimensions and adjusting torch speed and current values based on inclination angles.
Implementation Method 1
a 3D printer employing a metallic material melts the metal powder or metal wire using a heat source, such as a laser or an arc
Implementation Method 2
melting and solidifying a filler metal, thereby forming weld beads
Implementation Method 3
there is a possibility that the weld bead being formed drips due to the influence of gravity
Data Source
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AI summary
Provided are a method and device for manufacturing shaped objects with which it is possible to efficiently form weld beads without any defects such as sagging or humping, and shape shaped objects. When using a torch to form weld beads obtained by melting and solidifying a filler material, a map of bead heights and bead widths is created in advance, each bead height and width corresponding to a base surface incline angle formed between the perpendicular direction and a base surface on which a melt bead is to be formed and a trajectory incline angle formed between the perpendicular direction and the direction of the trajectory of the torch on the base surface. When a weld bead is formed on the base surface, a bead height and bead width are selected from the map in accordance with the base surface incline angle and the trajectory incline angle, and the weld bead is formed at the selected bead height and bead width.