Intermittent Welding Wire Feed for Consistent TIG Weld Seams
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding methods, particularly TIG welding, face challenges in maintaining consistent weld quality due to variations in welding parameters, such as distance and angle, leading to uneven weld seams and defects, especially when operated manually or with complex geometries.
Innovation Solution
The welding method involves feeding the welding wire in intermittent cycles with reversing feed speed, adjusting the feed speed parameters based on actual and predefined values of contact and non-contact durations with the molten bath, using a control unit to maintain consistent weld quality by continuously adapting to varying parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a constant feed speed is used for the welding wire, then the feed device is simple to operate, but the weld seam quality becomes uneven due to variations in distance and angle parameters
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant feed speed to a dynamic feed speed that varies continuously based on real-time monitoring of welding parameters. The control unit adjusts the feed speed according to detected variations in distance and angle, allowing the system to adapt to changing conditions and maintain consistent weld quality throughout the welding process.
Solution Approach 2:
The patent implements feedback by using sensors to continuously monitor welding parameters (distance and angle) and feeding this information back to the control unit. The control unit then adjusts the feed speed based on this feedback, creating a closed-loop control system that automatically compensates for parameter variations and maintains optimal welding conditions.
2Productivity
If the welding wire is fed continuously at high speed, then productivity is improved, but the welding wire may dip too deeply into the molten bath or lose contact, causing defects
Solution Approach 1:
The system uses dynamic feed speed adjustment to optimize both productivity and reliability. Rather than using a fixed high speed, the feed speed is continuously varied based on real-time welding conditions, allowing the system to maintain high productivity when conditions are optimal while preventing defects when parameters vary, thus achieving both high speed and consistent quality.
Solution Approach 2:
Feedback control prevents welding defects by continuously monitoring welding parameters and adjusting the feed speed accordingly. When the system detects that the welding wire is dipping too deeply or losing contact, it automatically adjusts the feed speed to prevent these conditions, thereby maintaining reliable weld quality while sustaining high productivity through minimal interruptions.
3Device complexity
If manual operation is used to adjust welding parameters, then device complexity is reduced, but manufacturing precision deteriorates due to human error in maintaining distance and angle
Solution Approach 1:
The patent uses feedback control to automatically compensate for variations in welding parameters. Sensors continuously monitor distance and angle, and the control unit adjusts the feed speed to maintain consistent weld quality, eliminating the need for manual adjustment while achieving superior precision and uniformity compared to manual operation.
Solution Approach 2:
The system performs self-adjustment by automatically detecting parameter variations and correcting feed speed without human intervention. This self-service capability allows the welding system to maintain optimal parameters throughout the process, achieving high precision while minimizing the need for complex manual control mechanisms.
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 ensures high-quality, uniform weld seams by automatically adjusting feed speed parameters, reducing adverse effects from manual operation or complex geometries, and improving welding consistency.
Implementation Method 1
an arc is generated between the electrode and the workpiece, which on the one hand produces the molten bath on the workpiece
Implementation Method 2
the welding wire is likewise melted by the energy of the arc in order to produce a weld seam on the workpiece
Implementation Method 3
an electric heating current can also be introduced into the welding wire in order to electrically heat the welding wire and to assist in the melting of the filler material
Data Source
AI summary
A welding method and to a corresponding welding device including a heat source and a welding filler material in the form of a welding wire, to achieve a welding quality that is as high and consistent as possible simply and independently of the skill of the welder. The welding wire is fed to the molten bath in intermittent feed cycles; while carrying out the method, an actual value is determined for a duration of a first time period of the feed cycles in which the welding wire does not contact the molten bath, and/or an actual value is determined for a duration of a second time period of the feed cycles in which the welding wire does contact the molten bath; and at least one predefined parameter of the feed speed of the welding wire is changed in the feed cycles, depending on the determined actual value and a predefined target value.