Welding Condition Determination for Consumable Electrode Arc Welding

Solution Overview

Problem

Inexperienced operators in consumable electrode arc welding often spend a significant amount of time and waste materials trying to set optimal welding conditions, such as welding current, voltage, and speed, due to the lack of efficient methods for determining suitable parameters.

Innovation Solution

A method and device that calculate and display recommended welding conditions based on the object and welding method information, including welding current, voltage, wire feed speed, welding speed, and leg length, allowing for automatic adjustment and display of new values if changes are made, thereby reducing operator effort and material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If inexperienced operators set welding conditions manually through trial and error, then they can eventually find suitable welding parameters, but they waste significant time and materials in the process

Engineering Contradiction:

Improvewelding condition accuracyVSAvoidtime to set welding conditions

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system pre-calculates and stores optimal welding condition data in a database before actual welding operations. When welding parameters are needed, the system retrieves pre-determined values based on material type, thickness, and joint configuration, eliminating the need for operators to perform trial-and-error adjustments during production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention introduces a welding condition determination system as an intermediary between the operator and the welding process. This system includes a database storing pre-determined conditions and a determination unit that automatically selects appropriate parameters, acting as a mediator that translates material specifications into optimal welding settings without requiring operator expertise.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If inexperienced operators set welding conditions manually through trial and error, then they can eventually find suitable welding parameters, but they waste significant materials during the process

Engineering Contradiction:

Improvewelding condition accuracyVSAvoidmaterial waste

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The system pre-calculates and stores optimal welding condition data in a database before actual welding operations. When welding parameters are needed, the system retrieves pre-determined values based on material type, thickness, and joint configuration, eliminating the need for operators to perform trial-and-error adjustments during production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention introduces a welding condition determination system as an intermediary between the operator and the welding process. This system includes a database storing pre-determined conditions and a determination unit that automatically selects appropriate parameters, acting as a mediator that translates material specifications into optimal welding settings without requiring operator expertise.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If expert operators set welding conditions based on knowledge and experience, then welding conditions can be determined quickly, but this approach requires high operator skill level

Engineering Contradiction:

Improvespeed of setting welding conditionsVSAvoidoperator skill requirement

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The welding condition determination system performs the function of expert operators automatically without human intervention. The determination unit autonomously queries the database, retrieves pre-stored optimal conditions based on input parameters, and outputs welding settings, making the expert knowledge embedded in the system self-sufficient and independent of operator skill level.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention introduces a welding condition determination system as an intermediary between the operator and the welding process. This system includes a database storing pre-determined conditions and a determination unit that automatically selects appropriate parameters, acting as a mediator that translates material specifications into optimal welding settings without requiring operator expertise.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP2617508B1Welding condition determining method, and welding device

Publication Date: 2017.07.05 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

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AI summary

A method to determine welding conditions includes relational expressions or tables about various parameters for setting welding conditions. The method can determine and display the recommended values for the welding conditions which are suitable for the information about the object to be welded and the information about the welding method set by the operator. The welding conditions include a welding current, a welding voltage, a wire feed speed, a welding speed, and a leg length. Furthermore, if the operator changes the recommended value for a welding condition to a new value, the method can determine new recommended values for the other welding conditions compatible with the new value and display the new recommended values.