Welding Control Apparatus for Droplet Supply Regularity
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Solution Overview
Problem
Existing arc welding methods using carbon dioxide gas as a shielding gas face issues with droplet irregularity, increased spatters, and fumes due to disturbances, leading to disrupted droplet supply regularity and prolonged recovery times.
Innovation Solution
A welding control apparatus with a droplet separation detecting unit and a waveform generator that alternately generates first and second pulses, and outputs a third pulse with different pulse parameters if droplet separation is not detected within a certain period, to forcibly separate or reshape the droplet and restore regularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pulse welding is applied to carbon-dioxide-gas-shielded arc welding to supply one droplet at each pulse, then droplet supply regularity is improved, but the system becomes complex and requires precise control of multiple pulse parameters
Solution Approach 1:
The welding current is divided into distinct pulse periods with different current levels. High current periods accelerate droplet separation, while low current periods allow droplet formation without excessive spatter generation. This segmentation of the welding process into functional phases enables reliable droplet supply while maintaining controllable system complexity.
Solution Approach 2:
The welding apparatus employs periodic pulse welding with alternating high and low current periods. This periodic action creates regular droplet separation cycles, ensuring one droplet is supplied at each pulse while the repeating pattern simplifies control compared to continuous complex parameter adjustment.
2Speed
If high pulse current is used to accelerate droplet separation, then droplet separation speed is improved, but spatter generation increases
Solution Approach 1:
The system applies a low current period following the high current period to counteract the harmful effects of excessive current. This preliminary anti-action reduces spatter generation by lowering the current after droplet separation has been initiated, while the initial high current ensures rapid droplet separation.
Solution Approach 2:
By alternating between high current periods (for rapid separation) and low current periods (for spatter reduction), the system achieves both fast droplet separation and minimal spatter generation through periodic modulation of the welding current.
3Manufacturing precision
If pulse parameters are adjusted to maintain droplet supply regularity when contact tip to base metal distance changes, then welding quality is improved, but control complexity increases
Solution Approach 1:
The pulse welding parameters are designed to dynamically adapt to changes in contact tip to base metal distance. The alternating high and low current periods provide flexibility in responding to distance variations, maintaining droplet supply regularity and welding quality without requiring overly complex control mechanisms.
Solution Approach 2:
The system utilizes changes in pulse current levels and periods to compensate for variations in contact tip to base metal distance. By adjusting these parameters within the pulse welding framework, the system maintains welding quality while avoiding the need for entirely complex control systems.
4Device complexity
If conventional single pulse waveform is used, then device simplicity is maintained, but droplet supply regularity deteriorates under disturbance
Solution Approach 1:
The welding current is segmented into alternating high and low current periods within a single pulse waveform. This segmentation enables the system to respond to disturbances by adjusting the timing and duration of these periods, maintaining droplet supply regularity while keeping the waveform generator relatively simple compared to multi-waveform systems.
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 reduces the time necessary to return to normal operation and minimizes spatters and fumes by ensuring consistent droplet supply and maintaining arc stability.
Implementation Method 1
accelerate constriction of the droplet by means of electromagnetic pinch force to allow the droplet to separate from wire
Implementation Method 2
allow the droplet to separate from wire before an arc force presses the droplet back to the wire
Data Source
AI summary
The present invention provides a welding control apparatus including: a droplet separation detecting unit that detects separation of a droplet from a tip end of welding wire; and a waveform generator that alternately generates a first pulse for separating the droplet and a second pulse for shaping the droplet and outputs the generated pulse to a welding power source, the waveform generator generating a third pulse having a pulse shape different in a pulse peak current and/or a pulse width from the second pulse to output the generated third pulse to the welding pulse source after a base time of the first pulse if separation of the droplet is not detected within a peak period, a falling slope period, or a base period of the first pulse to thereby restore a droplet supply regularity.