Welding Power Source Voltage Control via Current Zone Segmentation
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Solution Overview
Problem
Consumable electrode arc welding experiences unstable arc length control due to abnormal voltages superimposed on the welding voltage, which are not effectively removed by conventional methods, leading to decreased welding quality, especially in non-pulse welding processes.
Innovation Solution
The method involves segmentalizing the welding current into zones, setting a norm welding voltage for each zone, detecting current and voltage at minute cycles, calculating a fluctuation range, and limiting the welding voltage to this range to remove abnormal voltages, with optional moving averages and approximating curves for automatic calculation under given conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional output control based on welding voltage is used, then the control system is simple, but abnormal voltages destabilize arc length control leading to decreased welding quality
Solution Approach 1:
The welding current application range is segmentalized into multiple current zones, with a norm welding voltage value set for each zone. This segmentation allows the system to handle different current levels with appropriate voltage expectations, improving the detection accuracy of abnormal voltages while maintaining a structured control approach.
Solution Approach 2:
A norm welding voltage value serves as an intermediary reference for comparing actual welding voltage. By introducing this reference value that represents normal operating conditions, the system can identify abnormal voltages without requiring complex control mechanisms, thus improving reliability while keeping the control system relatively simple.
2Measurement precision
If experimental setting of norm voltage values is required, then control precision can be improved, but the process becomes time-consuming and less adaptable
Solution Approach 1:
The welding power source automatically calculates the norm welding voltage value based on detected welding current and stored current-voltage characteristic data, eliminating the need for manual experimental setting. The system serves itself by using its own operational data to establish reference values, thereby improving detection accuracy without requiring external calibration time.
Solution Approach 2:
Current-voltage characteristic data is stored in advance in the storage unit, allowing the system to quickly retrieve and use pre-established relationships between current and voltage. This preliminary preparation enables the system to automatically determine norm values without performing time-consuming experiments during operation.
3Speed
If the welding power source responds quickly to voltage changes, then control responsiveness is improved, but stability may be compromised due to abnormal voltages
Solution Approach 1:
The system continuously detects welding voltage and current, compares actual voltage against the norm welding voltage value, and uses this feedback to identify abnormal voltages. This feedback mechanism allows the system to respond quickly to genuine arc length changes while filtering out abnormal voltages that would otherwise cause instability, thus achieving both high responsiveness and stability.
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 stabilizes arc length control and improves welding quality by effectively removing abnormal voltages, eliminating the need for experimental setting of norm values and allowing high-response voltage control adjustments.
Implementation Method 1
anode point is formed at a tip of the welding wire while a cathode point is formed at the base metal surface, whereby an arc is formed between the anode point and the cathode point
Data Source
AI summary
In the output control method for a consumable electrode arc welding power source, entire application range of an welding current is segmentalized into a plurality of current zones, a norm welding voltage value is set for each of the current zones, a welding current and a welding voltage are detected at each of minute cycles, the current zone which corresponds to a detected value of the welding current is selected, a fluctuation range is calculated with the norm welding voltage value of the selected current zone as a center value, a welding voltage limit value is calculated while the welding voltage detected value is limited to within the fluctuation range, and the output of the welding power source is controlled based on this welding voltage limit value.