Synergic Welding Power Control for Burn-Through and Fusion
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Solution Overview
Problem
Conventional welding power supplies struggle to adjust output power effectively during welding operations, particularly when dealing with workpieces of varying thickness and geometry, leading to issues like burn-through and lack of fusion.
Innovation Solution
A welding power supply system that allows for synergic control of output power by simultaneously adjusting voltage and wire feed speed, using a manually accessible control on the torch, enabling operators to change deposition modes on-the-fly and finely control heat input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional welding power supplies use fixed or limited adjustment ranges for voltage and wire feed speed, then the device complexity is reduced and ease of operation is improved, but the adaptability to varying workpiece conditions deteriorates
Solution Approach 1:
The patent combines voltage control and wire feed speed control into a single synergic control mechanism. When the operator adjusts the synergic control parameter, the system automatically coordinates changes in both voltage and wire feed speed according to pre-established relationships, eliminating the need for separate controls and reducing operational complexity while maintaining adaptability.
Solution Approach 2:
The system implements dynamic adjustment of welding parameters during the welding process. The synergic control allows real-time modification of voltage and wire feed speed based on varying workpiece conditions, enabling the welding parameters to adapt dynamically rather than remaining fixed or requiring manual adjustment of multiple independent parameters.
2Adaptability or versatility
If conventional welding power supplies allow wide independent adjustment ranges for voltage and wire feed speed, then the adaptability to varying workpiece conditions is improved, but the ease of operation deteriorates due to difficulty in coordinating multiple parameters
Solution Approach 1:
The patent merges voltage control and wire feed speed control into a single synergic control parameter. The operator adjusts only one parameter (the synergic control parameter), and the system automatically coordinates the corresponding adjustments in voltage and wire feed speed, greatly simplifying operation while maintaining the ability to adapt to varying workpiece conditions.
Solution Approach 2:
The system performs self-coordination of multiple welding parameters based on the single synergic control input. The control system automatically determines the appropriate voltage and wire feed speed settings based on pre-established relationships, eliminating the need for the operator to manually coordinate multiple independent parameters.
3Manufacturing precision
If conventional welding power supplies use preselected fixed parameters, then the ease of operation is improved, but the manufacturing precision deteriorates when welding workpieces of varying thickness and geometry
Solution Approach 1:
The system transitions from static preselected parameters to dynamic real-time adjustment. The synergic control mechanism allows the operator to modify welding parameters during the welding process to match varying workpiece conditions, ensuring consistent weld quality across workpieces of different thicknesses and geometries while maintaining operational simplicity.
Solution Approach 2:
The patent implements systematic parameter changes through the synergic control mechanism. As the operator adjusts the synergic control parameter, both voltage and wire feed speed are changed in a coordinated manner according to pre-established relationships, allowing adaptation to varying workpiece conditions while maintaining proper parameter coordination for consistent weld quality.
Data Source
AI summary
Methods and apparatus to synergically control a welding-type output during a welding-type operation are disclosed. An example welding-type power supply includes a power conversion circuit configured to convert input power to welding-type power and to output the welding-type power to a welding-type torch; a communication circuit configured to receive a control signal from a remote control device during a welding-type operation; and a control circuit configured to synergically control a voltage of the welding-type power and a wire feed speed based on the control signal.