Welding Wire Feed Control for Short Circuit Opening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding devices face interruptions and welding defects when attempting to open a short circuit with low-melting-point welding wires, leading to inefficiencies and quality issues due to overcurrent protection functions.
Innovation Solution
The method involves stopping, slowing, or reversing the feeding of the welding wire after reaching a predetermined current value during a short circuit to facilitate the opening of the short circuit, reducing unnecessary interruptions and improving weld quality and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large current is supplied to open a short circuit with low-intrinsic-resistivity welding wire (e.g., aluminum), then the short-circuit current increases, but the welding wire continues to be semi-molten and the short circuit fails to open
Solution Approach 1:
The wire feed speed is reduced before the short circuit is opened, preventing additional wire from being fed into the molten pool during the current increase phase. This preliminary action ensures that when large current is applied, the wire tip remains in a stable position, allowing the short circuit to open successfully without the wire remaining semi-molten and stuck
Solution Approach 2:
The wire feed speed is dynamically adjusted based on the welding state. During short circuit conditions, the feed speed is automatically reduced to prevent wire buckling and ensure proper short circuit opening, while returning to normal speed when the short circuit opens. This dynamic control adapts the feeding process to the real-time electrical and mechanical state of the welding system
2Reliability
If the short circuit does not open smoothly, then welding may be interrupted due to overcurrent protection function, but this protects the welding device and welding jigs from overcurrent
Solution Approach 1:
The wire feed speed is reduced in advance during short circuit conditions, which prevents wire buckling and ensures the short circuit opens smoothly. This preliminary speed reduction eliminates the root cause of overcurrent situations, allowing welding to continue without triggering overcurrent protection while still protecting the system from actual overcurrent damage
Solution Approach 2:
The invention converts the potentially harmful effect of reduced wire feed speed (which might seem to slow down welding) into a beneficial effect by preventing wire buckling and ensuring reliable short circuit opening. This prevents overcurrent conditions and welding interruptions, ultimately improving welding continuity and quality while the system remains protected from overcurrent damage
3Reliability
If wire feed speed is not controlled during short circuit, then welding wire may buckle, but controlling feed speed adds complexity to the wire feed system
Solution Approach 1:
The wire feed controller receives feedback about the welding state (short circuit detection) and automatically adjusts the wire feed speed accordingly. This feedback mechanism allows the system to reduce feed speed during short circuits to prevent buckling, then restore normal speed when the short circuit opens, achieving reliable wire feeding without requiring complex manual intervention or additional hardware
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 effectively reduces welding defects and enhances production efficiency by ensuring the short circuit opens without triggering overcurrent protection, resulting in high-quality welds and shorter weld times.
Implementation Method 1
welding output unit that generates a welding output
Implementation Method 2
current detector that detects a welding current
Implementation Method 3
voltage detector that detects a welding voltage
Data Source
AI summary
In a method and device for performing welding, after the welding current reaches a first current value during a short circuit, the feeding of the welding wire is stopped, slowed down, or moved backward. As a result, the opening of a short circuit is urged to reduce the frequency at which welding is unnecessarily interrupted by an overcurrent protection function. This achieves high weld quality such as the absence of welding defects, and high production efficiency.