Welding Travel Speed Pacing for Consistent Penetration Control

Solution Overview

Problem

New and inexperienced welders often produce poor weld quality due to inadequate understanding of proper travel speed techniques, leading to inconsistent speeds and burn-through issues in thinner materials.

Innovation Solution

A travel speed pacing system that includes an interface to input welding operation characteristics, determining a target travel speed and outputting indicators such as audio, visual, or haptic signals to guide the welder, using marked locations on the workpiece to maintain consistent speed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If welders move the welding tool slowly to ensure proper penetration, then weld penetration is improved, but burn-through occurs in thinner materials

Engineering Contradiction:

Improveweld penetrationVSAvoidburn-through

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The system provides real-time feedback to the welder through visual indicators (LED lights) and audio signals that respond to the welding torch's position and travel speed. The feedback mechanism monitors welding parameters and immediately communicates whether the welder is moving at the correct speed, allowing continuous adjustment to prevent burn-through while maintaining proper penetration.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual skill-based speed control with an automated electronic control system that uses sensors, microprocessors, and output devices to regulate travel speed. This substitution transforms the mechanical skill of maintaining consistent speed into an automated feedback-controlled system that objectively enforces proper welding parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If welders move the welding tool faster to increase productivity, then welding speed is improved, but weld quality deteriorates due to insufficient penetration

Engineering Contradiction:

Improvewelding speedVSAvoidweld quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system provides real-time feedback to the welder through visual indicators (LED lights) and audio signals that respond to the welding torch's position and travel speed. The feedback mechanism monitors welding parameters and immediately communicates whether the welder is moving at the correct speed, allowing continuous adjustment to prevent burn-through while maintaining proper penetration.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual skill-based speed control with an automated electronic control system that uses sensors, microprocessors, and output devices to regulate travel speed. This substitution transforms the mechanical skill of maintaining consistent speed into an automated feedback-controlled system that objectively enforces proper welding parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If welders maintain inconsistent travel speeds due to lack of experience, then ease of operation is improved, but weld quality becomes inconsistent

Engineering Contradiction:

Improveoperational flexibilityVSAvoidweld consistency

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system provides real-time feedback to the welder through visual indicators (LED lights) and audio signals that respond to the welding torch's position and travel speed. The feedback mechanism monitors welding parameters and immediately communicates whether the welder is moving at the correct speed, allowing continuous adjustment to prevent burn-through while maintaining proper penetration.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system enables the welder to self-correct by providing immediate feedback that allows the operator to adjust their own performance in real-time. The welder receives continuous guidance through visual and audio cues, enabling them to maintain proper speed without requiring extensive training or external supervision.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20240342837A1Travel speed pacing systems and methods for welding-type operations

Publication Date: 2024.10.17 ILLINOIS TOOL WORKS INC

AI summary

Disclosed example travel speed pacing systems for welding-type operations include: an interface configured to receive an input describing a characteristic of a welding-type operation; and control circuitry configured to: determine a target travel speed based on the input; determine a target time interval at which the welding-type operation is to traverse locations corresponding to successive ones of a plurality of marked locations on the workpiece of the welding-type operation, the target time interval being based on the target travel speed and a unit distance between the marked locations; and control the interface to output indicators representative of a target time interval.