Welding Wire Feed Speed Control for Spatter Reduction
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Solution Overview
Problem
Conventional consumable electrode arc welding methods face challenges in maintaining stability and reducing spatter due to external disturbances, such as changes in the distance between the welding tip and the workpiece, leading to uneven bead width and increased spatter generation.
Innovation Solution
A consumable electrode arc welding method and device that control the wire feed speed cyclically between forward and backward feeds, with adaptive control mechanisms to maintain a stable arc state by stopping cyclic changes and applying constant control if a short circuit does not occur within predetermined conditions, ensuring consistent short circuit generation and arc regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire feed speed is controlled cyclically to forcibly cause short circuit and arc regeneration, then welding speed increases and productivity improves, but spatter generation increases and welding stability deteriorates when external disturbances occur
Solution Approach 1:
The patent implements feedback control by detecting whether a short circuit has occurred within predetermined time periods and adjusting the wire feed speed cyclicality accordingly. When no short circuit occurs within the first predetermined time period, the cyclic wire feed speed control is stopped and constant speed control is applied, preventing spatter and maintaining welding stability while still achieving high productivity when conditions are favorable.
2Object-generated harmful factors
If the short circuit is opened without depending on electromagnetic pinch force, then spatter is reduced, but welding stability deteriorates when distance between tip and base material changes
Solution Approach 1:
The patent applies dynamic control by making the wire feed speed control strategy adaptive based on real-time welding conditions. The system transitions between cyclic control mode (for normal operation) and constant speed control mode (when distance changes occur), allowing the control parameters to change dynamically in response to feedback signals, thus maintaining both low spatter and high stability.
3Stability of the object's composition
If wire feed speed is accelerated during arc period and decelerated during short circuit period, then arc regeneration is achieved, but bead width uniformity deteriorates when short circuit timing varies
Solution Approach 1:
The patent applies preliminary action by detecting in advance whether a short circuit will occur within the predetermined time period before completing a full wire feed cycle. When no short circuit occurs within the first predetermined time period, the system proactively stops the cyclic speed variation and maintains constant wire feed speed, preventing the conditions that lead to non-uniform bead width while ensuring arc regeneration continues through the second predetermined time period.
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 reduces spatter and achieves a uniform bead width by enhancing the stability of the arc, even in the presence of external disturbances, thereby improving the overall welding process.
Implementation Method 1
welds the wire onto a workpiece to be welded by alternately generating a short circuit state and an arc condition between the consumable electrode and the workpiece
Implementation Method 2
the short circuit is opened without depending on electromagnetic pinch force of welding current
Data Source
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AI summary
If a short circuit does not occur during deceleration of a wire feed speed in forward feed of a welding wire before the wire feed speed reaches a predetermined wire feed speed, a cyclic change is stopped and the wire feed speed is constantly controlled at the first feed speed. If a short circuit occurs during forward feed at the first feed speed, deceleration from the first feed speed starts, and the cyclic change is resumed for welding. This achieves uniform weld bead without increasing spatters even if any external disturbance such as change of distance between a tip and base material occurs.