Welding System Voltage Compensation via Waveform Feedback
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Solution Overview
Problem
Welding systems face quality issues due to voltage errors caused by the inductance and resistance of secondary components like weld cabling, which existing solutions often address inadequately, particularly in cluttered environments where additional cables are undesirable.
Innovation Solution
A welding system and method that compensates for voltage errors by using a controller to analyze weld waveforms, calculate a compensated stud voltage, and adjust weld commands to account for inductance and resistance errors in weld cabling, eliminating the need for additional voltage sensing leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a non-current carrying voltage sensing lead is added to sense voltage at the weld without being affected by voltage error, then voltage measurement accuracy is improved, but device complexity and cable clutter increase
Solution Approach 1:
The system measures the actual voltage at the weld and compares it to the commanded voltage, then uses this feedback to calculate and apply a compensation value that corrects for the voltage error introduced by the secondary cabling inductance and resistance
Solution Approach 2:
The system dynamically adjusts the weld voltage command by adding a compensation value derived from the measured voltage error, effectively changing the control parameter to account for the secondary component characteristics
2Manufacturing precision
If voltage sensing leads are added to compensate for cable voltage errors, then weld quality is improved, but ease of operation deteriorates due to cluttered weld environment
Solution Approach 1:
The controller continuously monitors the voltage at the weld and uses this feedback to automatically adjust the weld parameters, eliminating the need for physical voltage sensing leads at the weld location and thus maintaining ease of operation
Solution Approach 2:
The system replaces the mechanical solution of adding physical voltage sensing leads with an electrical/control solution that uses existing cables and a controller to achieve voltage error compensation
3Ease of manufacture
If secondary components with inductance and resistance are used in weld cabling, then ease of manufacture is improved, but voltage error increases leading to decreased weld quality
Solution Approach 1:
The system performs preliminary characterization of the secondary cabling inductance and resistance, then uses this information to pre-calculate compensation values that are applied during welding to maintain weld quality
Solution Approach 2:
The system converts the harmful effect of voltage error caused by secondary component inductance and resistance into a measurable parameter that is used to calculate compensation, effectively turning the problem into a solution
Data Source
AI summary
A method includes receiving data corresponding to a weld waveform that is generated during a welding operation and determining, based on the received data corresponding to the weld waveform, an overshoot voltage for the welding operation that exceeds an expected voltage level. The method further includes receiving data corresponding to a measured stud voltage and calculating, based on the overshoot voltage and the measured stud voltage, a stud voltage for the welding operation. The method also includes controlling at least one parameter of the welding operation based on the stud voltage for the welding operation.