Welding Power Source Current Control for High-Heat Low-Spatter Welding
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Solution Overview
Problem
Existing welding technologies struggle to achieve high heat input and efficient spatter reduction, especially when welding thick plates, due to limitations in current range and heat penetration.
Innovation Solution
A welding power source with a control unit that adjusts the welding current based on the periodic position of the wire's distal end relative to the base metal, incorporating a low-current period during reverse feeding and a high-current period during forward feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If short-circuit transfer mode with periodic forward and reverse feeding is used, then spatter generation is reduced, but applicable current range is limited and heat input is insufficient for thick plate welding
Solution Approach 1:
The patent applies periodic action by implementing periodic forward feeding and reverse feeding of the welding wire in synchronization with periodic variation of welding current. The wire feeding speed is modulated periodically to create forward feeding periods (increasing wire extension) and reverse feeding periods (decreasing wire extension), while the welding current is simultaneously varied periodically. This coordinated periodic action enables droplet transfer control with reduced spatter while maintaining high heat input capability for thick plate welding.
2Object-generated harmful factors
If low current range is used for short-circuit transfer, then spatter is reduced, but penetration depth is insufficient for thick plates
Solution Approach 1:
The patent applies dynamics by making both the wire feeding speed and welding current dynamically variable rather than constant. The wire feeding speed is dynamically adjusted through periodic forward and reverse feeding, creating time-varying wire extension. Simultaneously, the welding current is dynamically varied in synchronization. This dynamic coordination enables the system to achieve both spatter reduction and adequate penetration depth by optimizing the temporal relationship between wire position and current application.
3Length of moving object
If high current is applied for thick plate welding, then penetration is improved, but spatter generation increases
Solution Approach 1:
The patent applies feedback by using the detected wire extension (distance from wire distal end to base metal surface) as a feedback signal to control the wire feeding speed and welding current. The wire extension serves as a measurable parameter that provides feedback about the welding state, enabling automatic adjustment of feeding speed and current to maintain optimal welding conditions. This feedback mechanism allows high current to be applied for penetration while preventing excessive spatter through real-time control.
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 enables efficient welding with high heat input and reduced spatter generation, even at high current ranges, ensuring better penetration and weld quality on thick plates.
Implementation Method 1
Gas shielded arc welding is used for welding of automobiles, steel frames, construction machinery, shipbuilding, and various other industries
Implementation Method 2
a first welding current (Iw1) is applied, and thereafter, a second welding current (Iw2) smaller than the first welding current (Iw1) is applied
Data Source
AI summary
A welding power source is configured to supply a welding current to a wire as a consumable electrode. The welding power source includes a controller configured to change the welding current based on a position of a distal end of the wire a distance from which to a surface of a base metal varies periodically, in a case where the distal end of the wire is fed toward the base metal with periodical switching between a forward feeding period and a reverse feeding period.