Welding Power Supply Timing for Overlapping Spot Weld Control
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Solution Overview
Problem
Conventional welding techniques for thin metal often result in burn-through due to excess current, inadequate travel speed, poor weld fit-up, insufficient metal thickness, improper travel angle, and poor energy control, leading to inefficiencies and operator strain.
Innovation Solution
The use of a welding power supply system with a spot timer and a stitch timer to control the duration and overlap of sequential welds, adjusting parameters such as wire feed speed and voltage to reduce burn-through and improve weld uniformity and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding techniques are used on thin metal, then welding can be performed, but burn-through occurs due to excess current and poor energy control
Solution Approach 1:
The patent implements periodic action by using a spot timer to create discrete, timed weld spots rather than continuous welding. The welder makes multiple separate welds at different locations, allowing heat to dissipate between welds and preventing cumulative heat buildup that causes burn-through. This periodic welding approach transforms continuous heat input into controlled, intermittent heat application.
Solution Approach 2:
The patent applies segmentation by dividing the welding process into multiple separate spot welds instead of one continuous weld. The stitch timer controls the sequence and timing of these segmented welds, creating a series of discrete welding events. This segmentation distributes the thermal load across multiple locations and time periods, preventing localized overheating and burn-through.
2Area of stationary object
If multiple overlapping spot welds are made manually, then weld coverage can be achieved, but operator strain increases and weld consistency decreases
Solution Approach 1:
The patent implements self-service by using automated timers (spot timer and stitch timer) to control the welding sequence, duration, and overlap. The system automatically manages the timing and positioning of multiple welds without requiring manual intervention for each weld parameter adjustment. This automation reduces operator physical strain and mental workload while ensuring consistent weld coverage and overlap.
Solution Approach 2:
The patent applies feedback principles through the control system that monitors and regulates the welding process based on pre-set timer parameters. The timers provide temporal feedback control, ensuring each weld is made at the correct time with the correct duration and overlap, automatically adjusting the welding sequence to maintain consistency and reduce operator variability.
3Manufacturing precision
If welding parameters are not controlled, then welding process is simple, but spatter increases and weld uniformity decreases
Solution Approach 1:
The patent applies dynamics by implementing time-varying control through the spot timer and stitch timer. The control system dynamically adjusts welding parameters based on temporal sequences, controlling the duration of each weld spot and the time intervals between welds. This dynamic temporal control ensures consistent energy delivery and weld characteristics while maintaining relatively simple hardware architecture.
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 reduces the likelihood of burn-through, minimizes spatter, and enhances the consistency and speed of the welding process, reducing operator strain and improving the overall quality of the weld.
Implementation Method 1
excess current...improper weld settings (e.g., too much heat)...the power supply does not properly control the delivery of energy
Implementation Method 2
a sequence of multiple welds...controlling the arc duration of each weld
Data Source
AI summary
Disclosed example welding power supplies include: power conversion circuitry configured to convert input power to welding power; and control circuitry configured to: set a spot timer representative of an arc duration for a plurality of sequential arc welds; set a stitch timer representative of a duration between sequential ones of the sequential arc welds; and in response to initiation of welding, controlling the power conversion circuitry to perform the plurality of sequential arc welds by controlling the arc duration of each of the plurality of sequential arc welds based on the spot timer and controlling the duration between the sequential ones of the sequential arc welds based on the stitch timer, wherein the spot timer and the stitch timer are set to cause sequential ones of the sequential arc welds to overlap.