Welding Trigger Control for Periodic Sensor and Actuator Timing
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Solution Overview
Problem
Conventional welding systems lack flexibility in specifying and changing trigger conditions for sensors and process actuators connected to the welding current source, limiting their adaptation to periodically varying process parameters and hindering optimal control during welding processes.
Innovation Solution
A user interface connected to the welding current source allows for flexible specification and transfer of trigger conditions to sensors and process actuators via ports, enabling optimal synchronization with periodically varying process parameters, and includes features like pre-triggering to compensate for delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional welding systems use fixed trigger conditions for sensors and actuators, then the system structure is simple, but the adaptability to periodically varying process parameters is poor
Solution Approach 1:
The patent implements dynamic trigger conditions that can be adjusted in real-time based on the periodic process parameters. The trigger conditions are no longer fixed but can be modified according to the varying welding parameters, allowing the system to adapt dynamically to periodic changes in the welding process while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent changes the parameters of the trigger conditions to match the periodic variations in welding parameters. By adjusting the trigger conditions' parameters (such as timing, thresholds) to correspond with the periodic process parameters, the system achieves adaptability without requiring a completely complex restructured system.
2Manufacturing precision
If trigger conditions are predefined and cannot be modified, then the device complexity is low, but the control precision during welding processes is limited
Solution Approach 1:
The patent allows trigger conditions to be specified and configured in advance through a user interface before the welding process begins. This preliminary configuration enables precise control to be established beforehand, matching the trigger conditions to the specific periodic process parameters of the welding task, thereby improving control precision without adding complexity during the actual welding operation.
3Reliability
If sensors and actuators are triggered without flexible trigger conditions, then the ease of operation is high, but the monitoring and control effectiveness is reduced
Solution Approach 1:
The patent implements a user interface that enables operators to independently configure and adjust trigger conditions according to their specific welding process requirements. This self-service capability allows operators to optimize monitoring and control effectiveness without requiring complex system reconfiguration or expert intervention, maintaining ease of operation while improving reliability.
Data Source
AI summary
A welding system has a welding current source providing a process parameter that varies periodically with a period; a process controller specifying the period of the process parameter; a power unit; a sensor for acquiring process variables when triggered and/or a process actuator for influencing process parameters when triggered; and a port connecting the sensor and/or the process actuator to the welding current source. At least one of the sensor and the process actuator is triggered by the periodically varying process parameter according to a predefined trigger condition. A user interface connected to the welding current source is operable to specify the predefined trigger condition for triggering the sensor and/or the process actuator within the period of the process parameter and to set a defined trigger signal. If the predefined trigger condition is satisfied, the defined trigger signal is transferred via the port to the sensor and/or the process actuator.