Consumable Electrode Welding Control for Uniform Weld Seam Ripples
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Solution Overview
Problem
Conventional welding processes experience fluctuations in short-circuit cycle times during the cold welding phase, leading to uneven weld seam scales and quality issues, particularly when a higher number of short-circuit cycles are used.
Innovation Solution
Specifying a certain number of short-circuit cycles for the cold welding phase and determining the cold phase duration based on a calculated cold phase time, ensuring that any started short-circuit cycle is completed before switching to the warm welding phase, and optionally using a tolerance time to prevent new cycles from starting at the end of the cold phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a higher number of short-circuit cycles are used in the cold welding phase, then productivity increases, but fluctuations in short-circuit cycle times cause uneven weld seam scales and quality issues
Solution Approach 1:
The patent applies periodic action by using a fixed number of short-circuit cycles (e.g., 5 cycles) in each cold welding phase, creating a regular and predictable welding rhythm. This periodic approach ensures that the cold phase duration is consistent across multiple welding operations, resulting in uniform weld seam scales while maintaining high productivity through the optimized cycle count.
2Quantity of substance
If the cold phase duration is extended to complete more short-circuit cycles, then more material is deposited, but the varying cycle times cause inconsistency in weld seam characteristics
Solution Approach 1:
The patent changes the parameter of cold phase duration from a time-based value to a cycle-count-based value (e.g., exactly 5 short-circuit cycles). This parameter transformation ensures that material deposition is controlled by a fixed number of cycles rather than a variable time period, achieving consistent weld seam characteristics while optimizing the quantity of material deposited through the selected cycle count.
3Productivity
If the number of short-circuit cycles is increased to improve welding efficiency, then productivity increases, but the cold phase duration becomes harder to control precisely
Solution Approach 1:
The patent segments the cold welding phase into a discrete number of short-circuit cycles (e.g., 5 cycles) rather than using a continuous time measurement. This segmentation approach simplifies control by counting complete cycles, eliminating the need for precise timing measurements and making it easier to maintain consistent cold phase durations even as the number of cycles increases for higher productivity.
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 fluctuations in the cold phase duration, resulting in a more even weld seam scale and improved quality by ensuring that short-circuit cycles are not interrupted, thereby maintaining consistent weld seam characteristics.
Implementation Method 1
an arc between the electrode and the base material is lit by an electrical voltage or an electrical current resulting from the electrode and the area surrounding the electrode of the base material, causing a fabric -friendly connection
Implementation Method 2
a welding process with a melted electrode in which at least two different times sequential welding phases are used after igniting a arc between the electrode and a raw material
Data Source
Figure 1
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Figure 4a~4c
AI summary
In order to further develop a welding method such that an even ripple profile of a weld seam can be guaranteed, even with a higher number (n) of short circuit cycles (Ζκη), according to the invention, a determined number (n) of short circuit cycles (ZKn) are specified for the cold-welding phase (Pk) and the cold phase duration (DK) of the cold-welding phase (Pk) is determined in a number (n) of short circuit cycles (Ζκη) exceeding a predefined threshold cycle number according to a determined cold phase time, and the hot-welding phase (Pw) is entered after the cold-welding phase (PK).