AC Pulse Welding Waveform with Short-Circuit Droplet Transfer

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing welding technologies face challenges in maintaining consistent arc stability and preventing droplet scattering during AC pulse arc welding, leading to suboptimal welding quality.

Innovation Solution

A welding apparatus and method that alternately outputs positive and negative peak currents with interposed base periods, accompanied by controlled movement of the consumable electrode to temporarily short circuit the electrode and workpiece, ensuring efficient droplet transfer and improved arc stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If AC pulse arc welding is performed with alternating positive and negative polarity currents, then welding penetration and bead formation are improved, but arc stability deteriorates due to difficulty in controlling droplet transfer during polarity transitions

Engineering Contradiction:
Improvewelding qualityVSAvoidarc stability
Core Design Contradiction:
Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies periodic action by implementing a cyclic current waveform that alternates between positive and negative polarity peak currents with base currents in between. This periodic variation in current polarity and magnitude enables controlled droplet transfer during each half-cycle while maintaining overall arc stability through the repeating pattern, directly resolving the contradiction between achieving good welding penetration and maintaining arc stability.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent employs dynamics by making the current parameters dynamic rather than static. The welding current continuously varies through four distinct phases (positive peak, base, negative peak, base) within each cycle, with polarity and magnitude changing dynamically. This dynamic current control adapts to the droplet formation and transfer process at different stages, improving both welding quality and arc stability simultaneously.

Inventive Principle:
Principle #15Dynamics

2Productivity

If peak current is increased to improve droplet transfer, then welding penetration is enhanced, but droplet scattering increases during polarity transitions

Engineering Contradiction:
Improvewelding efficiencyVSAvoiddroplet scattering
Core Design Contradiction:
ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent applies segmentation by dividing the welding current into distinct segments or phases: positive peak current, base current, negative peak current, and base current. Each segment serves a specific function - the peak currents drive droplet formation and transfer, while the base currents provide transition periods. This segmentation allows high peak currents to be applied without continuous exposure, reducing droplet scattering while maintaining welding efficiency.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent uses periodic action by implementing alternating positive and negative peak currents separated by base currents. This periodic pattern allows droplets to be transferred during peak current phases while the base current phases provide recovery and transition periods that prevent excessive droplet scattering. The cyclic repetition of this pattern maintains welding efficiency while controlling harmful droplet dispersion.

Inventive Principle:
Principle #19Periodic action

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 enhances welding quality by reliably transferring droplets during base periods, reducing scattering and maintaining arc stability, thereby improving the overall welding process.

Implementation Method 1

a welding power source that outputs current between a consumable electrode and a workpiece

Methodology Applied
Scientific EffectElectric arc: Electric Arc

Implementation Method 2

outputting a positive peak current from the workpiece to the consumable electrode during a positive peak period

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11478871B2Welding apparatus and welding method
Publication Date: 2022.10.25 YASKAWA DENKI KK
  • US11478871B2 patent drawing
  • US11478871B2 patent drawing
  • US11478871B2 patent drawing

AI summary

An example welding apparatus includes a welding power source configured to output current between a consumable electrode and a workpiece; a feeding apparatus configured to move the consumable electrode toward the workpiece; and circuitry. The circuitry is configured to: control the welding power source to repeat a sequence including: outputting a positive peak current from the workpiece to the consumable electrode during a positive peak period; outputting a first base current between the consumable electrode and the workpiece during a first base period following the positive peak period, an absolute value of the first base current being less than the positive peak current; and outputting a negative peak current from the consumable electrode to the workpiece during a negative peak period following the first base period, an absolute value of the negative peak current being greater than the absolute value of the first base current. The circuitry is further configured to control the feeding apparatus to move the consumable electrode close to the workpiece so as to temporarily short circuit the consumable electrode and the workpiece during the first base period.