Welding Device Heat Input Control for Metallurgical Structure
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Solution Overview
Problem
Existing welding technologies require separate user adjustments for mechanical and electrical parameters to achieve the correct welding quality, lacking a direct connection between these parameters and heat input, making it difficult to achieve the desired metallurgical structure.
Innovation Solution
A method where the user defines the desired cooling behavior of the welding joint by inputting cooling time or heat input per unit length, allowing the welding device to adjust parameters like wire feed speed, welding current, and voltage to maintain the optimal heat input and power, ensuring the desired metallurgical structure is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate manual adjustments of mechanical and electrical parameters are made, then welding quality can be improved, but the complexity of operation increases and the connection between parameters and heat input becomes indirect
Solution Approach 1:
The patent transforms multiple welding parameters (wire feed speed, voltage, current) into a single controllable parameter - heat input per unit length. By calculating and controlling heat input directly, the system simplifies operator interaction while maintaining precise control over welding quality and metallurgical structure.
Solution Approach 2:
The patent introduces heat input per unit length as an intermediary parameter that mediates between mechanical parameters (wire feed speed) and electrical parameters (voltage, current). This intermediary provides a direct connection and unified control mechanism, eliminating the need for separate manual adjustments of multiple parameters.
2Manufacturing precision
If multiple welding parameters are adjusted manually, then welding quality can be controlled, but the time required for adjustment increases
Solution Approach 1:
By changing the control parameter from multiple separate parameters to a single heat input parameter, the system reduces adjustment time. The controller automatically calculates and adjusts all necessary parameters based on the desired heat input, eliminating time-consuming manual adjustments.
3Reliability
If the welding device automatically adjusts parameters based on material information, then the repeatability of welding quality improves, but the device complexity increases
Solution Approach 1:
The system incorporates feedback by reading material information (such as material type, thickness) and automatically adjusting welding parameters to achieve consistent heat input. This feedback mechanism ensures repeatability of welding quality across different materials and conditions.
Solution Approach 2:
The welding device performs self-adjustment by automatically calculating and modifying welding parameters based on material information without requiring manual intervention. This self-service capability improves consistency and repeatability while the automation handles the complexity internally.
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 method ensures consistent metallurgical structure in welding joints, independent of the welder, by automatically adjusting welding parameters to maintain the desired heat input and power, improving the quality and repeatability of the welding process.
Implementation Method 1
the amount of heat input to the welding joint during welding
Implementation Method 2
the subsequent cooling behaviour of the material
Implementation Method 3
measuring, during the welding, of thermal energy brought to the welding workpiece
Data Source
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AI summary
The object of the invention is a method for adjusting a welding parameter of a welding device, which method comprises steps, in which a desired cooling behaviour is predefined for the welding joint, information about the desired cooling behaviour of the welding joint is given to the welding device (100) by giving to the welding device (100) a cooling time t, an amount of heat input Qset, or material information about the material to be welded, after which the welding device (100), based on the given information and on preliminary information given to the welding device (100) in advance, determines and adjusts the values of welding parameters to be used in the welding in order to achieve the desired cooling behaviour of the welding joint, and that the welding device (100) either determines the actual heat input during welding Qact and, by adjusting at least one welding parameter, sets the actual heat input Qact to correspond, within the adjustment range, to the heat input Qset determined through the cooling time t or the material information, or to a given amount of heat input Qset, or that the welding device (100) calculates and monitors the power guide value Pset based on the heat input Qset, the measured or given travel speed V of the welding gun (103), and the thermal efficiency factor k, calculates and monitors the actual power Pact, and, by adjusting at least one welding parameter, sets the actual power Pact to correspond, within the adjustment range, to the power guide value Pset, or, by adjusting at least one welding parameter, sets the power guide value Pset to correspond, within the adjustment range, to the actual power Pact.