Welding Power Supply Switching Between DC and AC Without Arc Interruption
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Solution Overview
Problem
Existing welding power supply technologies lack the ability to seamlessly transition between DC and AC power outputs during a welding process, leading to potential fusion defects and the need for time-consuming chamfering processes, especially when dealing with complex geometries and varying welding conditions.
Innovation Solution
A method that allows for a seamless transition between DC and AC power outputs without interrupting the welding process, maintaining consistent welding speed and electrode feed speed, and adjusting the AC balance to adapt to changing welding conditions, such as arc blow and surface profiles, to prevent fusion defects and optimize weld penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate AC and DC terminals are provided in welding power supplies, then the power supply can support both AC and DC welding processes, but the device complexity increases and requires additional switching mechanisms
Solution Approach 1:
The patent implements a single output terminal that can function in both AC and DC modes through a controllable switch. The switch can be positioned to connect the output terminal to either the AC winding or DC winding of the transformer, allowing one terminal to serve multiple functions. This eliminates the need for separate AC and DC terminals while maintaining the capability to support both welding processes.
Solution Approach 2:
The patent introduces a dynamic switching mechanism that allows the welding power supply to transition between AC and DC modes during operation. The controllable switch can change the connection configuration in real-time, enabling the system to adapt its output characteristics dynamically based on welding requirements without requiring separate fixed terminals for each mode.
2Adaptability or versatility
If the welding process is interrupted to switch between DC and AC power outputs, then the power supply can change modes, but the welding quality deteriorates due to solidification or cooling of the weld puddle
Solution Approach 1:
The patent enables continuous welding operation during mode transitions by maintaining the arc and weld puddle throughout the switching process. The controllable switch is designed to transfer connection between AC and DC windings without interrupting the welding current flow to the output terminal. This ensures the weld puddle remains molten and continuous, preventing solidification defects and maintaining weld quality during power output mode changes.
Solution Approach 2:
The patent implements preliminary switching preparation by controlling the switch transition in advance of the actual mode change requirement. The system prepares the switching mechanism and maintains welding parameters that ensure smooth transition, preventing weld puddle cooling or solidification before the mode switch is completed.
3Manufacturing precision
If DC-positive electrode process is used for root run, then deep penetration is achieved, but subsequent filler runs require process change to AC for optimal results
Solution Approach 1:
The patent implements dynamic mode switching capability that allows the welding power supply to transition from DC-positive electrode process during root run to AC process for filler runs. The controllable switch enables this process change by reconfiguring the connection between the output terminal and the transformer windings, allowing the system to adapt to different welding stage requirements without external intervention.
Solution Approach 2:
The patent changes the electrical output parameters of the power supply by switching between different transformer windings. For root run, the system connects to DC winding providing DC-positive output for deep penetration. For filler runs, the system switches to AC winding providing AC output with different penetration characteristics suitable for filling operations. This parameter change is achieved through the controllable switch mechanism.
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 continuous welding without solidification or cooling of the weld puddle, reduces the need for chamfering, and effectively manages arc blow in complex geometries, ensuring high-quality welds by adapting to rapidly changing conditions.
Implementation Method 1
an electric arc between a consumable electrode and a work piece is generated
Data Source
AI summary
A method of operating a welding power supply during a welding process in which an electric arc between a consumable electrode and a work piece is generated while feeding the consumable electrode and moving the arc in relation to the work piece along a welding track, wherein a transition between a DC power output of the welding power supply and an AC power output of the welding power supply, or vice versa, is made without interruption of the welding process.