Weld Bead Parameter Mapping for Inclined Surface Build-Up
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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 traveling speed of the welding torch to prevent dripping can lead to humping, which breaks the weld bead.
Innovation Solution
A method and apparatus that use pre-calculated maps to select optimal bead heights and widths based on the base-surface inclination angle and track inclination angle, controlling the torch movement and welding parameters to prevent dripping and humping, by employing a torch, moving mechanism, memory unit, and control unit to form weld beads efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the traveling speed of the welding torch is increased to avoid dripping on inclined surfaces, then productivity is improved, but humping occurs causing weld bead breakage
Solution Approach 1:
The invention changes welding parameters (traveling speed, torch inclination angle, bead formation parameters) based on the base surface inclination angle. By dynamically adjusting these parameters according to the specific inclination conditions, the system maintains weld quality while improving productivity on inclined surfaces.
Solution Approach 2:
The invention performs preliminary measurement of the base surface inclination angle before welding, and pre-determines the optimal welding parameters based on the measured angle. This preliminary action allows the system to avoid humping and dripping by using pre-calculated appropriate parameters rather than attempting correction during welding.
2Device complexity
If conventional welding parameters are used on inclined surfaces, then device complexity is maintained, but dripping occurs reducing manufacturing precision
Solution Approach 1:
The welding system performs self-adjustment by automatically measuring the base surface inclination angle and selecting appropriate welding parameters from stored data. This self-service capability eliminates the need for complex external adjustment mechanisms while maintaining high welding precision on inclined surfaces.
Solution Approach 2:
The system uses feedback from the inclination angle measurement to automatically select and adjust welding parameters. The measured inclination angle feeds back into the control system, which then determines the optimal welding conditions, creating a closed-loop control that maintains precision without adding significant complexity.
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 method and apparatus effectively produce high-quality built-up objects by minimizing dripping and humping, ensuring efficient weld bead formation even on inclined surfaces, reducing takt time and maintaining weld quality.
Implementation Method 1
melting and solidifying a filler metal, thereby forming weld beads with a torch
Implementation Method 2
melting and solidifying a filler metal, thereby forming weld beads with a torch
Data Source
AI summary
A method for producing a built-up object, includes: producing maps beforehand, the maps indicating bead heights BH and bead widths BW corresponding to a base-surface inclination angle θ and a track inclination angle φ, in which the base-surface inclination angle is an angle between a base surface on which the weld beads are to be formed and a vertical direction, and the track inclination angle is an angle between a track direction of the torch and a vertical direction on the base surface; selecting a bead height BH0 and a bead width BW0 from the maps correspondingly to the base-surface inclination angle θ and the track inclination angle φ in forming a weld bead on the base surface; and forming the weld bead based on the selected bead height BH0 and bead width BW0.