Welder with Positional Heat Control for Weave Bead Penetration
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Solution Overview
Problem
Existing electric arc welding techniques struggle to effectively differentiate heat input between the center and edges of a weld bead during the weave technique, limiting the control of weld penetration and admixture in various applications.
Innovation Solution
An electric arc welder method that coordinates heat input by using a low heat process across the center of the weld bead and a higher heat process at the edges, with the transition between processes managed through time-based or audible cues for semi-automatic operations, and mechanized systems using digital controllers and flag signals for automated changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a weave technique is used to manipulate heat away from the center toward the edges, then heat distribution is improved, but the ability to differentiate heat input between center and edges is limited by how much heat can be manipulated by movement alone
Solution Approach 1:
The patent applies local quality by implementing different heat input procedures at different locations within the weld bead. Specifically, a low heat procedure is used across the center of the weave while a higher heat procedure is used at the edges. This spatial differentiation of thermal conditions allows precise control over penetration and admixture characteristics in different regions of the weld, directly resolving the limitation of conventional weave techniques that cannot sufficiently differentiate heat input between center and edges.
2Temperature
If a low heat procedure is used across the center of the weave, then penetration and admixture are reduced, but edge penetration may be insufficient
Solution Approach 1:
The patent implements local quality by applying distinct thermal procedures to different zones of the weld bead. The center region receives a low heat procedure that minimizes penetration and admixture, while the edge regions simultaneously receive a higher heat procedure that ensures adequate penetration. This zoned approach allows each region to receive the thermal input appropriate to its specific requirements, resolving the contradiction between reducing center penetration and maintaining edge penetration.
3Temperature
If a higher heat procedure is used at the edges of the weave, then penetration at the toes is improved, but admixture of base metal into weld metal increases
Solution Approach 1:
The patent applies local quality by implementing a higher heat procedure specifically at the edges of the weave where penetration is critical, while maintaining a low heat procedure across the center where admixture control is paramount. This spatially differentiated approach allows the edge regions to achieve adequate penetration without forcing the entire weld bead into a high heat mode that would increase admixture. The center region's low heat procedure prevents excessive base metal mixing while the edge regions independently achieve their penetration requirements.
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 approach allows for precise control of weld penetration and reduced admixture, enabling thinner weld beads with maintained alloy content at the edges and improved penetration at the toes of the weld, suitable for applications like hardfacing and open root butt joints.
Implementation Method 1
Welding current is created between a welding wire moving through a torch toward the workpiece
Data Source
AI summary
An electric arc welder for producing a weave pattern across a workpiece with a succession of individual weld short runs or bead, each of which has a center portion extending between two transversely spaced edges. The welder comprising a power source, a wire feeder to direct a welding wire through a movable torch to the workpiece and a controller for creating a welding current between the wire and the workpiece. A mechanical device is used to move the torch along the bead and the controller has a program to perform a first weld process while the torch is moving along the center portion and a second weld process when the torch is adjacent the edges, where the first weld process has less heat input than the second weld process.