Welding Wire Length Detection for Adaptive Arc Quality Control

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Solution Overview

Problem

Existing welding technologies face challenges in maintaining consistent weld quality due to variability in the parts being welded, such as non-identical geometry and random deformations, leading to issues with the length of free welding wire affecting the welding arc and pool shape, resulting in defects like lack of fusion or excessive energy input.

Innovation Solution

A method for detecting the length of welding wire protruding from the nozzle using image processing, which involves capturing images of the welding assembly, detecting the wire end and nozzle, and calculating the wire length through Euclidean distance, with steps to attenuate noise and enhance image processing for accurate detection, allowing for real-time adaptation of the welding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If the distance between the workpiece and the welding torch is increased, then the free welding wire length increases, but the arc intensity reduces and voltage increases, resulting in welding defects

Engineering Contradiction:

Improvefree welding wire lengthVSAvoidwelding quality

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The system continuously monitors the welding wire length using image processing and provides feedback to the control system. This feedback loop enables real-time adjustment of the welding torch position or wire feed rate to maintain optimal wire length, preventing arc intensity reduction and voltage increase that lead to welding defects

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces traditional mechanical wire length measurement systems with optical image processing. A camera captures images of the welding area, and image processing algorithms automatically determine wire length, eliminating the need for complex mechanical sensors and enabling more precise, real-time monitoring

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Length of moving object

If the distance between the workpiece and the welding torch is decreased, then the free welding wire length decreases, but the electrical current increases, risking damage to support materials and weld quality

Engineering Contradiction:

Improvefree welding wire lengthVSAvoidexcessive energy input

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

The continuous monitoring of wire length provides early warning before excessive current conditions develop. The control system can proactively adjust parameters to prevent damage to support materials and maintain proper weld quality by keeping wire length within optimal ranges

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system detects wire length variations before they cause harmful effects. By continuously monitoring and predicting trends, the control system can make preliminary adjustments to prevent excessive current and energy input before damage occurs

Inventive Principle:

Principle #10Preliminary action

3Productivity

If pre-programmed trajectories are used for automated welding, then welding efficiency is improved, but welding defects occur due to part variability and positioning variations

Engineering Contradiction:

Improvewelding efficiencyVSAvoidweld quality consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system transitions from static pre-programmed trajectories to dynamic adaptive control. Image processing continuously measures actual wire length and part position, and the control system dynamically adjusts welding parameters and torch position in real-time to compensate for part variability while maintaining high productivity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent enables real-time changes in welding parameters (current, voltage, speed, wire feed rate) based on actual measurements. This allows the system to adapt to part variability and positioning variations, maintaining weld quality consistency without sacrificing the efficiency of automated welding

Inventive Principle:

Principle #35Parameter changes

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 real-time adjustment of the welding process to maintain optimal wire length, preventing defects by ensuring consistent weld quality even in variable conditions, thereby improving the reliability and precision of the welding operation.

Implementation Method 1

a camera (37) capable of capturing images of an assembly (E) formed by the welding nozzle (24), the welding wire (25), the welding arc (26) and the welding bath (27)

Methodology Applied

Scientific EffectLight detection: Photoelectric Effect

Data Source

PatentEP4074450B1Method of detecting a length of feedwire by image processing, and corresponding memory comprising instructions for implementing such process

Publication Date: 2024.01.31 WEEZ-U WELDING

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Figure 4a~4b

AI summary

The present invention relates to a method for detecting a length (L) of welding wire (25) protruding from a welding nozzle (24) belonging to a welding torch comprising: a detection step by image processing of a free end (42) of the welding wire (25), a detection step by image processing of the welding nozzle (24), and a calculation step of a length (L) of the welding wire (25) protruding from the welding nozzle (24) by a calculation of the Euclidean distance between the end of the welding wire (25) and the welding nozzle (24).