Arc Welding Waveform Display for Weaving Tracking Adjustment
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Solution Overview
Problem
Existing arc-tracking welding techniques fail to provide clear and recognizable information about welding current waveforms during the welding process, leading to difficulties in achieving accurate tracking and often result in meandering or defective welds due to the need for trial and error adjustments of welding conditions and parameters.
Innovation Solution
An arc welding display device and method that display the welding current or voltage waveforms sectioned by fixed periods, including weaving periods, with average values subtracted and superimposed waveforms to help workers visualize deviations and adjust parameters accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the welding current waveform is displayed simply on a screen, then the display is simple, but the worker cannot visually and easily grasp the relation to the deviation from the waveform
Solution Approach 1:
The welding current waveform is segmented into multiple periods, with each period corresponding to one complete weaving operation. This segmentation allows the worker to analyze each weaving cycle independently, making it easier to understand the relationship between waveform characteristics and tracking deviations without being overwhelmed by the entire waveform at once.
Solution Approach 2:
The patent transforms the one-dimensional waveform display into a two-dimensional analysis by adding time-period segmentation. Each period is displayed as a separate segment with temporal progression, allowing workers to visually trace the deviation patterns across multiple weaving cycles and grasp the relationship between waveform asymmetry and tracking errors more easily.
2Manufacturing precision
If the worker adjusts welding conditions and tracking parameters through repeated trial and error, then the worker can obtain a desired locus, but this causes loss of time and reduces productivity
Solution Approach 1:
The patent implements a feedback mechanism by displaying segmented welding current waveforms that show asymmetry patterns during weaving operations. This real-time visual feedback allows workers to immediately see the relationship between waveform characteristics and tracking deviations, enabling rapid parameter adjustment without repeated trial and error, thus improving both tracking accuracy and productivity.
Solution Approach 2:
The patent enables preliminary analysis of welding parameters by displaying segmented waveforms before final welding operations. Workers can adjust tracking parameters and welding conditions based on the visualized waveform patterns from test runs, optimizing settings in advance to avoid time-consuming trial and error during actual production welding.
3Ease of operation
If the worker confirms arc-tracking by observing only the operation locus of the robot, then the confirmation process is simple, but the worker cannot clearly grasp why the arc-tracking has deviated
Solution Approach 1:
The patent merges the operation locus observation with welding current waveform analysis by displaying segmented waveforms that correspond to specific portions of the welding path. This combination allows workers to simultaneously observe both the robot's movement path and the electrical characteristics, providing comprehensive information about tracking performance and deviation causes without complicating the confirmation process.
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 workers to confirm and adjust welding conditions and tracking parameters in real-time, reducing the occurrence of meandering or defective welds by providing clear visual feedback on the welding current or voltage waveforms, thereby improving the accuracy and efficiency of arc-tracking welding.
Implementation Method 1
In arc welding, 'arc-tracking' is used commonly in which a deviation of a wire tip position from a joining position of welding is detected on the basis of a variation such as a welding current or a welding voltage
Data Source
AI summary
An arc welding display device is included in a welding apparatus having a weaving function of swinging a torch with respect to a welding direction. The arc welding display device displays, on a screen, at least one of a welding current and a welding voltage during the arc welding with a range sectioned by each fixed period including at least one weaving period.