Welding Wire Surface Scanning With Adaptive Contact Error Detection
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Solution Overview
Problem
Conventional scanning systems for metal workpieces experience measurement inaccuracies due to high acceleration forces and surface abrasion of welding wires, leading to slippage and compromised results, especially when using soft materials like aluminum.
Innovation Solution
A method and device using a blowtorch with a welding wire electrode that moves relative to the workpiece surface, detecting contact and adjusting movement profiles and frequencies to minimize acceleration and abrasion, with automatic detection of surface wear and adaptive conveyance to reduce measurement errors, and using electric motor signals to monitor and adjust drive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the wire end is repeatedly moved towards and away from the workpiece surface using drive rollers, then the workpiece surface can be scanned and measured, but high acceleration forces occur leading to wire surface abrasion and slippage
Solution Approach 1:
The patent replaces the mechanical drive roller system with an acoustic field-based measurement approach. The welding wire electrode is used as a probe that interacts with the workpiece surface through controlled contact, and measurements are obtained by detecting electrical signals (such as contact resistance or capacitance changes) rather than relying on mechanical force transmission through drive rollers. This eliminates the mechanical slippage and abrasion problems while maintaining measurement capability.
Solution Approach 2:
The patent changes the movement parameters of the wire end, specifically controlling the scanning speed and acceleration to remain below threshold values that would cause surface abrasion. By limiting the acceleration and speed parameters during scanning, the system prevents wire surface degradation and maintains stable contact without the need for high-force drive rollers.
2Productivity
If drive rollers apply compressive forces on the wire to maintain contact, then the wire can be conveyed along the scanning path, but surface abrasion increases leading to wire deformation and reduced gripping forces
Solution Approach 1:
The patent replaces the mechanical drive roller conveyance system with a controlled movement system that uses the welding wire's own flexibility and the blowtorch's positioning capabilities. The wire is conveyed by feeding it through the blowtorch at controlled rates, and positioning is achieved by moving the blowtorch along the scanning path rather than using drive rollers to mechanically push the wire. This eliminates compressive forces and associated abrasion while maintaining scanning productivity.
Solution Approach 2:
The patent introduces dynamic adjustment of wire feed rate and blowtorch movement speed to optimize the scanning process. The system adapts the conveying speed and scanning speed in real-time to maintain optimal contact conditions without excessive compressive forces, preventing wire deformation and measurement errors while sustaining productivity.
3Speed
If high acceleration forces are applied to the wire during scanning, then the scanning speed can be increased, but slippage between the wire and drive rollers occurs compromising measurement results
Solution Approach 1:
The patent replaces the drive roller mechanical transmission system with a direct positioning system where the blowtorch and wire feed mechanism work together to achieve controlled movement. The scanning speed is controlled by coordinating the wire feed rate with the blowtorch movement speed, eliminating the need for mechanical force transmission through drive rollers and preventing slippage-related measurement errors.
Solution Approach 2:
The patent changes the acceleration and speed parameters to remain below threshold values that would cause slippage. By controlling the wire feed rate and blowtorch movement speed to stay within optimal ranges, the system achieves accurate measurements without compromising scanning productivity, replacing the need for high acceleration mechanical drive systems.
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 measurement accuracy by reducing slippage and wear on the welding wire electrode, leading to more precise scanning results and extended electrode life by adapting movement and contact points to maintain consistent contact and minimize thermal stress.
Implementation Method 1
contact of a wire end of the piece of wire with the workpiece surface of the workpiece is detected
Data Source
AI summary
Method for scanning a workpiece surface (2A) of a metal workpiece (2), in which a blowtorch (3) having a welding wire electrode (4) is moved relative to the workpiece surface (2A) to determine scanning values and a wire end (4A) of the welding wire electrode (4) is repeatedly moved towards the workpiece surface (2A), in each case until contact with the metal workpiece (2) at a scanning position (P) on the workpiece surface (2A) of the metal workpiece (2) is detected, and the wire end (4A) of the welding wire electrode (4) is subsequently moved back, the blowtorch (3) detecting scanning values (d) at scanning positions (P), at least in some cases multiple times, to determine scanning measurement errors.