Weld Ending Process for Arc Welding Wire Control
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Solution Overview
Problem
In electric arc welding, the electrode wire often continues to feed into the workpiece after the welder has stopped, causing contamination and difficulty in establishing a new arc due to response lag in the wire feeder, leading to issues like damage and hardened molten material buildup.
Innovation Solution
A wire material transfer routine is executed during the weld ending process, sensing contact between the welding wire and the workpiece, and repeatedly transferring molten material until the wire feeder stops advancing the wire, utilizing a droplet transfer routine to clear the electrode tip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire feeder stops feeding wire after the welder stops welding, then the welding process ends cleanly, but the response lag causes the electrode wire to continue feeding and contact the workpiece, causing contamination and hardened material buildup
Solution Approach 1:
The system performs preliminary action by detecting wire contact with the workpiece before the wire feeder actually stops feeding. When contact is detected during the weld ending process, the system executes a wire material transfer routine to transfer molten material from the welding wire to the workpiece, preventing contamination and hardened material buildup on the electrode tip.
Solution Approach 2:
The system uses feedback by continuously monitoring for wire contact with the workpiece during the weld ending process. This feedback mechanism triggers the wire material transfer routine only when contact is detected, allowing the system to respond dynamically to the actual wire feed status and prevent harmful effects without interfering with normal welding operation.
2Productivity
If the wire feeder has response lag stopping the wire, then the system can maintain continuous feeding during welding, but the wire continues to feed after welding stops, causing electrode damage
Solution Approach 1:
The system employs feedback by monitoring wire contact status during the weld ending process. When contact is detected, indicating the wire is still feeding due to response lag, the system activates the wire material transfer routine to prevent electrode damage while maintaining the productivity benefit of continuous feeding during active welding.
Solution Approach 2:
The system converts the harmful effect of continued wire feeding (which causes contact and damage) into a beneficial process by executing the wire material transfer routine. This routine uses the continued wire feed to transfer molten material to the workpiece, cleaning the electrode tip while the wire is still being fed, thus converting a harmful situation into a useful function.
3Reliability
If the wire feeder stops instantly, then electrode contamination is prevented, but the mechanical response lag makes instant stopping impossible, causing wire to contact workpiece
Solution Approach 1:
The system takes preliminary action by detecting wire contact before the wire feeder naturally stops due to response lag. This early detection allows the system to execute the wire material transfer routine during the period when the wire is still feeding, preventing electrode contamination without requiring the wire feeder to stop instantly.
Solution Approach 2:
The system uses the wire material transfer routine to self-correct the issue of continued wire feeding. By transferring molten material from the welding wire to the workpiece during the contact period, the system automatically cleans the electrode tip without requiring external intervention or faster wire feeder response.
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 prevents damage and ensures easier arc initiation for the next weld by removing hardened molten material, maintaining the electrode tip's condition and improving the welding process efficiency.
Implementation Method 1
In electric arc welding, a popular welding process uses a solid wire electrode fed with a wire feeder. At the start of welding, an arc must be established between the electrode tip and the workpiece.
Data Source
AI summary
An electric arc welding system and method includes providing a welding apparatus having at least a welding power supply, a wire feeder configured to supply a welding wire, a welding gun having an opening from which the welding wire extends, and a welding controller. The controller can initiate a weld ending process, which senses any contact between the welding wire and a workpiece. In response to any such contact, the controller executes a wire material transfer routine to transfer molten material of the welding wire from the welding wire to the workpiece. This routine can be repeated until the wire feeder stops advancing the welding wire towards the workpiece during the weld ending process.