Multi-Source Welding Heat Input Calculation for Accurate Process Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding systems fail to accurately account for the total heat input from multiple energy sources, including preheating energy, leading to incomplete understanding of the overall energy absorbed during welding operations.
Innovation Solution
A method and system to calculate the total heat input by summing the instantaneous power from all energy sources, including welding and preheating, using a processor to collect and sum average instantaneous power measurements from multiple power sources, and display or transmit the results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple energy sources (welding and preheating) are used in welding operations, then the total heat input increases and welding quality improves, but the ability to accurately measure and account for total heat input deteriorates
Solution Approach 1:
The patent combines multiple power sources (welding power source and preheating power source) into a single integrated system controlled by one controller. The controller receives power measurements from both sources and calculates their sum to determine total heat input, thereby merging separate measurement functions into a unified measurement approach that accurately captures total energy input.
Solution Approach 2:
The controller performs multiple functions: it controls both the welding power source and preheating power source, measures power from both sources, calculates total heat input by summing both power measurements, and outputs the combined heat input value. This multi-functional approach enables a single device to handle both separate energy sources and provide unified heat input measurement.
2Adaptability or versatility
If separate power sources are used for welding and preheating, then welding process flexibility improves, but system complexity increases
Solution Approach 1:
The controller is designed to perform multiple functions: controlling both welding and preheating power sources, measuring power from both sources, calculating total heat input, and outputting combined measurements. This multi-functional controller reduces overall system complexity despite the presence of multiple power sources.
Solution Approach 2:
The patent merges the control functions for separate welding and preheating power sources into a single controller that manages both sources. This consolidation simplifies the control architecture while maintaining the flexibility of using multiple power sources for different welding processes.
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
Enables accurate determination of total heat input without requiring additional data acquisition equipment, allowing operators to understand and optimize welding processes more effectively.
Implementation Method 1
an electrode preheating circuit configured to provide preheating power through a first portion of the welding-type electrode
Implementation Method 2
Electrical power is applied to the welding wire and a circuit is completed through the workpiece to sustain a welding arc that melts the electrode wire and the workpiece
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An example welding-type system, includes: a processor; and memory comprising machine readable instructions which, when executed, cause the processor to: collect a plurality of average instantaneous power measurements from a plurality of welding-type power sources associated with a single welding-type process; and determine a total power input to the welding-type process by summing the average instantaneous power measurements for each of the welding-type power sources.