Welding Torch Arc Initiation via Inverted Feed Motion
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Solution Overview
Problem
Conventional consumable electrode type welding methods face issues with unstable arc generation due to the need for reversing robot manipulator operations, leading to increased tact time, arc length extension, and the 'wire stick' phenomenon, which causes production line stops and inefficiencies.
Innovation Solution
A consumable electrode type welding method where the welding torch is moved in a direction away from the member to be welded while continuously feeding the welding wire, eliminating the need for reversing operations and stabilizing the arc early, thus reducing tact time and preventing wire stick phenomena.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the robot manipulator is moved to approach the welding wire leading end to the member to be welded and then reversed to generate an arc, then the arc start is enforced, but the response time and acceleration time increase, extending the tact time
Solution Approach 1:
The welding wire is fed in advance before the torch reaches the welding position, so that the wire leading end is already positioned near the member when the torch arrives, eliminating the need for reverse movement to generate the arc
Solution Approach 2:
Instead of moving the torch backward after contact to generate an arc, the invention feeds the wire forward continuously while moving the torch forward, inverting the conventional sequence of operations
2Reliability
If the welding torch is moved in the opposite direction to the welding wire feed direction to carry out retreating movement, then the arc is generated, but the arc length extends and arc stability deteriorates
Solution Approach 1:
The welding wire is fed continuously throughout the torch movement, maintaining constant wire supply and preventing arc length extension that would occur with intermittent feeding during reverse movement
Solution Approach 2:
The wire feed speed is dynamically adjusted to match the torch movement speed, maintaining optimal wire extension and arc stability during the welding process
3Reliability
If the robot manipulator performs reversing operation to move the welding torch away from the member to be welded, then the arc is generated, but the acceleration time and response time increase
Solution Approach 1:
The welding wire is positioned near the member in advance through continuous feeding, so that when the torch arrives at the welding position, the arc can be generated immediately without requiring reverse movement
Solution Approach 2:
The conventional method moves the torch backward to generate the arc, while this invention moves the torch forward continuously while feeding the wire, inverting the sequence to eliminate reverse movement and improve response speed
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 method reduces response and acceleration times, stabilizes the arc during welding start, minimizes 'burn-back' processing time, and maintains a proper wire shape, enhancing productivity by reducing unexpected stops and maintaining arc stability.
Implementation Method 1
a welding power supply device for applying a welding output into and between a member to be welded and the welding wire
Data Source
AI summary
In a consumable electrode type welding method, while feeding a welding wire 1, a welding torch 4 is moved by a robot manipulator 9 in a direction where the welding torch 4 is pulled apart from a base metal 7, so that an initial arc is generated while the welding wire 1 is separated from the base metal 7. This not only can eliminate the need for the reversing operation of the robot manipulator 9 and thus can reduce the waste time to thereby be able to reduce a tact time but also can stabilize an arc in the welding start portion and thus can reduce the “unexpected stop” effectively.