Reciprocating Wire Feed Control for Stable Arc Welding
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Solution Overview
Problem
Conventional arc welding methods experience instability and spattering due to immediate direction inversion of wire feeding during temporary abnormal phenomena like micro short circuits, preventing regular and stable arc welding.
Innovation Solution
The method involves alternately performing forward and reverse wire feeds during arc and short circuit states, with specific determination periods to maintain stable arc welding and prevent recurrence of abnormal phenomena by controlling wire feeding speed and direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If wire feeding direction is inverted immediately after short circuit detection, then short circuit opening speed is improved, but welding stability deteriorates due to temporary abnormal phenomena
Solution Approach 1:
The control device determines whether a short circuit is normal or abnormal by comparing the timing against the arc period before actually responding to it. This preliminary classification action allows the system to prepare appropriate responses in advance, preventing premature or incorrect wire feeding direction inversions that would cause instability.
Solution Approach 2:
The control device uses feedback from the arc period timing to determine the nature of the short circuit. By monitoring when the short circuit occurs relative to the arc period and using this information to adjust the wire feeding control, the system achieves stable welding while maintaining fast short circuit opening when needed.
2Speed
If wire feeding direction is inverted immediately upon arc occurrence, then arc establishment speed is improved, but welding stability deteriorates due to temporary abnormal phenomena
Solution Approach 1:
The control device performs preliminary determination by checking whether arc occurrence timing falls within a predetermined period after short circuit termination. This advance classification prevents premature wire feeding direction changes that would occur with immediate response, ensuring stable welding while maintaining fast arc establishment when appropriate.
Solution Approach 2:
The control device uses feedback from monitoring arc occurrence timing relative to the short circuit termination to determine whether to invert wire feeding direction. This timing-based feedback mechanism ensures that wire feeding control actions are taken only when appropriate, achieving both fast arc establishment and welding stability.
3Reliability
If wire feeding speed is increased to prevent continuous short circuit, then short circuit prevention is improved, but wire feeding control complexity increases
Solution Approach 1:
The control device changes the wire feeding speed parameter based on the determined short circuit type. By adjusting the wire feeding speed according to whether the short circuit is normal or abnormal, the system effectively prevents continuous short circuits while using a relatively simple control structure that only requires parameter adjustment rather than complex control logic.
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 stable arc welding by continuing wire feed during temporary abnormalities and reduces recurrence of micro or sudden arcs, maintaining consistent welding quality.
Implementation Method 1
an arc welding method of performing welding by alternately generating a short circuit state and an arc state while feeding a welding wire (20) as a consumable electrode
Implementation Method 2
welding by alternately generating a short circuit state and an arc state
Data Source
AI summary
An arc welding method preforms reciprocating wire feed so as to alternately perform forward feed and reverse feed. The arc welding method includes a normal arc welding step, a normal short circuit welding step, and an abnormal arc welding step. In the abnormal arc welding step, a short circuit state occurs at a second time point, which is before a lapse of a second period from a first time point at which an arc state occurs. Further, in the abnormal arc welding step, the reciprocating wire feed continues until a third time point after a lapse of a first period from the second time point. At the third time point, the reciprocating wire feed is stopped and the abnormal arc welding step is completed. From the third time point, the welding wire is decelerated and the reciprocating wire feed is restarted.