Welding Burner Ignition and Wire Feed Control
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Solution Overview
Problem
TIG welding faces issues with arc faults and interference in automated systems due to high-voltage pulse ignition of the primary arc, and the hot wire method's risk of overheating and melting, leading to suboptimal weld quality and arc blow effects.
Innovation Solution
A burner with a wire feed mechanism that can operate in two directions and a power feed device for controlled voltage and current application, allowing for ignition of the primary arc without high-voltage pulses, using an igniting arc to ionize the region between the non-melting electrode and workpiece, and a regulating device to coordinate current flow with the wire feed movement, preventing arc blow and ensuring efficient preheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage pulse is used to ignite the primary arc, then the arc ignition is achieved, but interference in the electronic control system of automated systems occurs
Solution Approach 1:
The welding wire serves as an intermediary element to generate an igniting arc that ionizes the gap between the non-melting electrode and workpiece, enabling primary arc ignition without direct high-voltage pulsing. The wire acts as a mediator that transfers the ignition function from the electrode-workpiece interface to the wire-workpiece interface, thereby eliminating electronic interference while maintaining reliable arc ignition
Solution Approach 2:
The welding wire is advanced to contact the workpiece before the primary arc ignition attempt, and an igniting current is applied to pre-heat and ionize the wire tip. This preliminary action creates a conductive plasma path that facilitates subsequent primary arc ignition without requiring high-voltage pulses, thus preventing electronic interference while ensuring reliable ignition
2Temperature
If the welding wire is heated too much by the heating current, then the wire tip melts quickly and drops off, but the short circuit is interrupted and an arc fault is formed
Solution Approach 1:
A measuring unit continuously monitors the voltage across the welding wire to detect when a short circuit is established between the wire tip and workpiece. The regulating device uses this feedback signal to automatically adjust the heating current, reducing it when contact is detected to prevent excessive heating and wire tip drooping, thereby maintaining welding process stability
Solution Approach 2:
The heating current parameter is dynamically adjusted based on the welding state. When a short circuit is detected (indicating wire tip contact with workpiece), the heating current is automatically reduced or switched off to prevent overheating and wire tip drooping. This parameter change prevents arc faults while maintaining the benefits of wire preheating during non-contact phases
3Manufacturing precision
If the heating current flows through the welding wire to preheat it, then the melting behavior of the filler material is improved, but arc blow may occur and affect the quality of the weld
Solution Approach 1:
The measuring unit detects voltage changes that indicate wire tip contact with the workpiece or welding bath. The regulating device responds to this feedback by coordinating the heating current with the wire feed movement, switching off or reducing the heating current when contact occurs to prevent arc blow, while maintaining it during non-contact phases to ensure proper wire preheating and melting behavior
Solution Approach 2:
The heating current is applied periodically in coordination with the wire feed mechanism's reciprocating motion. The current flows during the approach phase (when wire is moving toward workpiece without contact) to preheat the wire, and is interrupted during the contact phase to prevent arc blow. This periodic application optimizes both wire preheating and prevents harmful arc blow effects
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 solution enables precise control of the welding process, preventing arc faults and improving weld quality by maintaining a stable arc and uniform bead formation, suitable for automated applications and enhancing the efficiency of the welding method.
Implementation Method 1
The welding wire is heated by means of a power feed device in the burner. As long as a short circuit is established between the workpiece and the tip of the welding wire, the heating current introduced via the power input device flows through the forward end of the welding wire and heats it by ohmic heating.
Implementation Method 2
An igniting arc is generated between the tip of the welding wire and the workpiece by contacting the workpiece with the tip of the welding wire, igniting an ignition current and retracting the welding wire. The igniting arc ionizes the region between the non-melting electrode and the workpiece, so that the primary arc can be ignited without the high-voltage pulse or with a substantially lower voltage than was previously necessary.
Data Source
AI summary
Burner for a welding apparatus having a non-melting electrode, a wire feed device for a welding wire and a power feed device for introducing an electric heating current into the welding wire that is supplied. The wire feed device can be activated in two directions of advance and an electric voltage applied by the power feed device to the welding wire can be regulated to ignite an igniting arc between the tip of the welding wire and the workpiece.