Welding Arc Ignition Energy Control for Reliable Re-Ignition
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Solution Overview
Problem
Conventional arc welding methods fail to reliably ignite or re-ignite the welding arc between a consumable welding wire electrode and a workpiece due to inadequate consideration of the thermal state of the wire end, leading to arc breaks and welding start faults.
Innovation Solution
A method and device that determine the distance or time duration required for the wire end to contact the workpiece and adjust the ignition energy accordingly, using sensors to measure and set the ignition energy based on the thermal state, allowing for precise control of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact ignition is used, then the welding arc can be ignited, but the wire end may remain welded to the workpiece surface or arc breaks may occur due to inadequate ignition energy
Solution Approach 1:
The system performs preliminary measurement of the distance between wire end and workpiece surface before ignition occurs. Based on this pre-measured distance, the control system calculates and applies the appropriate ignition energy in advance, preventing welding start faults and arc breaks before they occur.
Solution Approach 2:
The system continuously monitors the actual distance between wire end and workpiece surface during the ignition process and compares it with the predetermined distance. Based on this feedback, the control system dynamically adjusts the ignition energy to ensure reliable arc ignition while preventing wire end welding to the workpiece surface.
2Reliability
If high ignition energy is applied, then arc ignition reliability improves, but wire end may become overheated or welded to workpiece
Solution Approach 1:
The system changes the ignition energy parameter dynamically based on the measured distance between wire end and workpiece surface. For larger distances, higher ignition energy is applied; for smaller distances, lower ignition energy is used. This adaptive parameter adjustment ensures reliable ignition while preventing wire end overheating and welding to the workpiece.
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 prevents arc breaks and welding start faults by ensuring optimal ignition energy is applied, enhancing the reliability and productivity of the arc welding process.
Implementation Method 1
By reason of the short-circuit, a high electrical current flows which causes the welding wire electrode to melt at its tip or at its welding wire end and ignites the welding arc
Implementation Method 2
The welding arc burns between the workpiece and the welding wire electrode, reaching temperatures of more than 4000 K
Data Source
AI summary
Method and device for igniting and/or re-igniting a welding arc (SLB) between a wire end of a consumable welding wire electrode (SDE) and a workpiece (W), comprising the steps of: determining (S1) a distance (S) or time duration required by the wire end of the consumable welding wire electrode, SDE, until contact or short-circuit with a surface of the workpiece (W); and igniting (S2) the welding arc (SLB) with an ignition energy, EZ, which is set in dependence upon the determined distance (S) or time duration.