Welding Current Compensation for Coupled Power Source Interference
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Solution Overview
Problem
Interfering coupling between welding circuits in a welding system leads to fluctuations in the arc length and welding process quality, which is difficult to mitigate due to the challenges in minimizing induction areas and appropriately laying welding circuit lines, especially in complex production conditions.
Innovation Solution
A method involving the calculation and application of a compensation voltage based on the welding current progression from a transmitting welding power source, using stored coupling factors to correct the measured voltage and regulate the welding current, thereby reducing the interfering influence between welding circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding circuits are laid close together to save space, then productivity increases, but interfering coupling between circuits worsens
Solution Approach 1:
The patent introduces a compensation voltage as an intermediary element that mediates between the interfering coupling and the welding process. The compensation voltage is calculated based on the coupling factor and the other welding current, then added to the measured welding voltage to counteract the interfering coupling effect, allowing circuits to be laid close together without suffering from interference
Solution Approach 2:
The patent implements a feedback mechanism where the welding voltage is continuously measured, the interfering coupling is calculated based on known coupling factors and other welding currents, and a compensation voltage is generated and applied in real-time to counteract the interference, enabling stable welding operation with closely spaced circuits
2Object-affected harmful factors
If coupling factors are minimized by increasing distance between circuits, then interfering coupling reduces, but device complexity and space requirements increase
Solution Approach 1:
The patent changes the electrical parameter (voltage) by introducing a compensation voltage that is calculated based on the coupling factor and other welding currents. This parameter change allows the system to operate with closely spaced circuits without suffering from interference, avoiding the need for complex spatial separation or specialized cable routing
3Reliability
If compensation voltage is applied to reduce interfering coupling, then welding current stability improves, but measurement and control complexity increases
Solution Approach 1:
The patent performs preliminary action by pre-calculating the coupling factors between circuits and storing them for use during welding operation. The compensation voltage is calculated in advance based on these stored coupling factors and the measured other welding currents, simplifying the real-time control process and improving welding current stability without excessive complexity
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 effectively reduces or eliminates the mutual influence between welding power sources, improving the welding process by compensating for induced voltages and maintaining consistent welding current, thus enhancing the quality of the weld seam.
Implementation Method 1
Interfering coupling between welding circuits in a welding system leads to fluctuations in the arc length and welding process quality
Implementation Method 2
subtracting the compensation voltage from a measured voltage, measured by a voltage measurement unit of the welding power source (receiving welding power source), so as to determine a corrected measured voltage
Implementation Method 3
regulating the welding current generated by the welding power source (receiving welding power source) as a function of the corrected measured voltage
Data Source
AI summary
Method for compensating an interfering influence on a welding current, provided by a welding power source (4) for welding a workpiece (3), from another welding power source (4′), comprising the steps of:(a) providing (SA) a compensation voltage (UKomp), which is calculated on the basis of a welding current progression provided by the other welding power source (4′);(b) subtracting (SB) the compensation voltage (UKomp) from a measured voltage (UMess), measured by a voltage measurement unit (8) of the welding power source (4), so as to determine a corrected measured voltage (U′Mess); and(c) regulating (SC) the welding current generated by the welding power source (4) as a function of the corrected measured voltage (U′Mess).