Welding Wire Surface Scanning After Slag Removal Feedback
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Solution Overview
Problem
Existing scanning methods for metallic workpieces using a welding torch with a consumable welding wire often fail to reliably detect contact due to an insulating slag layer, leading to interrupted or inaccurate scanning processes.
Innovation Solution
A slag-removal process is implemented before scanning, where the welding current is minimized, and the wire is moved cyclically forward and backward over the workpiece until a short circuit is detected, with repeated cycles ensuring complete slag removal, and the process is terminated upon reaching a defined number of consecutive short circuits or changes in wire feed speed and force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a welding wire is used to scan the surface of workpieces by detecting short circuits, then the scanning process can be performed, but slag deposition on the welding wire blocks short circuit detection and interrupts the scanning process
Solution Approach 1:
The patent applies preliminary action by performing a slag-removal process before the scanning process. The welding wire is moved cyclically forward and backward over the workpiece surface with minimized welding current to remove slag deposits beforehand, ensuring that the subsequent scanning process can reliably detect short circuits without interruption.
Solution Approach 2:
The patent converts the harmful effect of slag deposition into a beneficial process by using the cyclic forward-backward movement with minimized current to deliberately remove slag. The same welding wire that gets contaminated during scanning is used to remove slag through controlled contact, transforming the contamination problem into a self-cleaning mechanism.
2Reliability
If a slag-removal process is performed before scanning with cyclic forward/backward movement, then slag is removed from the welding wire, but the process requires additional time and repeated cycles
Solution Approach 1:
The patent uses feedback by monitoring whether short circuits are detected during the slag-removal process. The process continues with repeated cyclic movements until short circuit detection occurs, indicating slag has been removed. This feedback mechanism automatically determines when the slag-removal process is complete, optimizing the duration based on actual conditions rather than using a fixed time.
Solution Approach 2:
The patent applies partial action by performing only the necessary number of cyclic movements required to remove slag, as determined by the feedback from short circuit detection. Rather than performing a fixed number of cycles regardless of need, the process stops as soon as slag removal is confirmed, avoiding excessive time consumption.
3Ease of manufacture
If the welding current is minimized during slag removal, then slag can be removed effectively, but the process requires precise control of current and movement parameters
Solution Approach 1:
The patent applies self-service by using the workpiece surface itself as the medium for slag removal. The welding wire contacts the workpiece surface during cyclic movements, and the mechanical contact combined with minimized current naturally removes slag without requiring additional cleaning devices or complex control systems. The system uses its own components to perform the cleaning function.
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
Ensures reliable and uninterrupted scanning by effectively removing slag, preventing false triggers and ensuring error-free detection of the workpiece surface, allowing for safe and accurate scanning only after confirmed slag removal.
Implementation Method 1
until contact of the welding wire with the workpiece is detected by a welding current source
Data Source
AI summary
In a method for scanning the surface of metallic workpieces, during scanning, a welding torch with a consumable welding wire is moved over and towards the workpiece surface, until contact of the welding wire with the workpiece is detected, and the welding wire is subsequently moved away from the workpiece. Before scanning, slag-removal is carried out to remove slag at the welding wire end, wherein the welding current is lowered to a minimum, and the welding wire is moved cyclically with a rapid recurrent forward/backward movement over a specified path length toward the workpiece, and by a smaller distance away from the workpiece, until a short circuit between the welding wire and the workpiece is detected, whereupon slag-removal is ended, and upon the detection of no short circuit, slag-removal is repeated, and upon the detection of several short circuits one after the other, slag-removal is ended.