Welding Torch Surface Marking Using Controlled Spark Motion
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Solution Overview
Problem
Conventional welding systems do not provide an efficient method for marking metal workpieces before or after the welding process without additional technical outlay.
Innovation Solution
A method and device using a welding torch with a meltable welding wire electrode that moves towards and away from the workpiece surface to produce electric sparks, causing material removal or alteration, allowing for marking without additional hardware, with controlled voltage and current to adjust the marking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional welding systems are used without additional equipment, then device complexity is reduced, but marking capability is lost
Solution Approach 1:
The welding system is enhanced to perform dual functions: welding and marking. The marking function is achieved by utilizing the existing welding power source to generate electric sparks through controlled contact and separation of the welding wire electrode with the workpiece surface, eliminating the need for separate marking equipment while adding marking capability to the conventional welding system
2Adaptability or versatility
If additional marking equipment is added to welding systems, then marking capability is improved, but device complexity increases
Solution Approach 1:
The marking function is merged with the welding system by using the welding power source and welding wire electrode for both welding and marking operations. The control unit integrates marking control with welding control, combining two functions into one system to avoid additional equipment while maintaining marking capability
3Manufacturing precision
If electric sparks are generated for marking, then material removal and alteration are achieved, but wire electrode sticking may occur
Solution Approach 1:
The welding wire electrode is moved in a periodic manner towards and away from the workpiece surface, creating controlled short circuits that generate electric sparks for marking. This periodic motion prevents continuous contact that would cause sticking, while still achieving effective material removal and alteration through repeated spark generation
Solution Approach 2:
The control unit monitors the welding process and adjusts parameters to prevent wire electrode sticking while maintaining effective marking. By controlling the timing and duration of wire contact with the workpiece, the system generates sufficient electric sparks for precise marking while avoiding conditions that would cause the wire to stick to the surface
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
Enables effective marking of metal workpieces for identification and labeling without disrupting the welding process, allowing for data display and quality control through adjustable marking parameters and movement profiles.
Implementation Method 1
an electric voltage present at the welding wire electrode and/or an electric current flowing through the welding wire electrode bring about electric sparks, which bring about material removal and/or material alteration at the workpiece surface
Implementation Method 2
the welding wire electrode consists of an additive material which can be melted during a welding process
Data Source
AI summary
Method and device for marking a workpiece surface (2A) of a metal workpiece (2), in which a welding torch (3) comprising a welding wire electrode (4) is guided along the workpiece surface (2A) to be marked and meanwhile a wire end (4A) of the welding wire electrode (4) is moved towards and away from the work-piece surface (2A) to be marked, wherein an electric voltage (U) present at the welding wire electrode (4) and/or an electric current (I) flowing through the welding wire electrode (4) bring about electric sparks, which bring about material removal and/or material alteration at the workpiece surface (2A) of the metal workpiece (2) to mark the workpiece surface (2A).