Automated Welding Torch Positioning for Faster Arc Ignition
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Solution Overview
Problem
Conventional automated welding methods with consumable welding wires experience significant delays during the ignition process due to the creep phase, leading to increased cycle times, especially when dealing with multiple welding seams.
Innovation Solution
The creep phase is integrated into the movement phase, where the welding wire is moved towards the workpiece at a specified forward speed until contact is detected, then moved away, and this sequence is repeated until the start position is reached, minimizing the distance between the wire end and the workpiece, thus reducing the creep phase duration to milliseconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the creep phase is carried out after the welding torch reaches the start position with a very low wire feed speed, then stable arc ignition is achieved, but the cycle time increases significantly due to delays of 50-500 ms per welding seam
Solution Approach 1:
The patent applies preliminary action by performing the creep phase during the movement phase, before the welding torch reaches the start position. The welding wire is advanced towards the workpiece during torch positioning, so that when the torch arrives at the start position, the wire is already very close to or in contact with the workpiece, eliminating the need for a separate post-positioning creep phase and reducing ignition delay
Solution Approach 2:
The patent merges the movement phase and creep phase into a single integrated process. Instead of executing the creep phase separately after positioning, the wire feeding during creep is combined with the torch movement, allowing both positioning and wire approach to occur simultaneously, thereby reducing total cycle time
2Productivity
If the wire feed speed during creep phase is increased to reduce delay, then cycle time is reduced, but arc ignition stability deteriorates
Solution Approach 1:
By performing the wire approach during the movement phase at optimized speeds, the system prepares the wire for contact before the actual welding ignition is required, allowing the use of higher speeds during positioning without compromising ignition stability, since the critical low-speed approach occurs just before contact
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 significantly reduces the influence of ignition delays on cycle time, optimizing the welding process by allowing the welding process to start quickly with minimal distance bridging, and reduces the consumption of protective gas.
Implementation Method 1
until a first contact of the welding wire end with the workpiece is detected
Implementation Method 2
The ignition process is initiated by means of the welding current source in that the wire feed is started, and the no-load voltage is applied to the welding wire
Data Source
AI summary
A method for preparing an automated welding method for a welding process moves a welding torch with a consumable welding wire during a movement phase at a positioning speed from an actual to a desired start position of a welding seam, and bridges the distance of the welding wire end from the workpiece during a creep phase. The creep phase is at least partially carried out during the movement phase. The wire is moved toward the workpiece at a first specified forward feed speed until a first wire end-workpiece contact is detected, moved away from the workpiece after first contact detection and then recurrently moved away from the workpiece, and the contact is interrupted again upon detection of further contacts, and the movement of the welding wire towards the workpiece and movement away from the workpiece after the contact is repeated until the start position is reached.