Wire Feed Controller for Consistent Welding Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inconsistent wire deposition rates during welding operations due to changes in contact tip to work distance (CTWD), which affect shorting frequency and result in varying wire feed speeds, leading to inconsistent metal deposition and adverse welding effects.
Innovation Solution
A method and system for controlling wire feed speed independently of welding parameters like voltage and current, using a processor-based controller to adjust wire advancement and retraction pulses to maintain a consistent average wire feed speed, separate from arc voltage and current control, ensuring consistent consumable deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire manipulation is used to clear short circuits quicker, then welding operation efficiency is improved, but wire feed speed consistency deteriorates
Solution Approach 1:
The system dynamically adjusts wire feed speed in real-time based on detected short circuit conditions. The controller monitors welding parameters and modifies wire feed speed dynamically to clear shorts quickly while maintaining overall deposition consistency, resolving the contradiction between rapid short clearing and feed speed stability.
Solution Approach 2:
The system employs feedback control by continuously monitoring welding parameters (voltage, current, wire feed speed) and using this information to adjust wire feed speed. The controller detects short circuits through parameter changes and responds by adjusting wire feed speed to clear the short while compensating to maintain consistent deposition rates.
2Adaptability or versatility
If contact tip to work distance changes during welding, then wire manipulation flexibility is improved, but deposition rate consistency deteriorates
Solution Approach 1:
The system monitors welding parameters that change with CTWD variations and uses feedback control to adjust wire feed speed accordingly. When CTWD changes affect shorting frequency and deposition rate, the controller detects these changes and modifies wire feed speed to compensate, maintaining consistent deposition despite CTWD variability.
Solution Approach 2:
The system changes wire feed speed as a control parameter in response to CTWD variations. By adjusting this parameter dynamically, the system compensates for the effects of changing CTWD on deposition rate, allowing flexible wire manipulation while maintaining deposition consistency.
3Manufacturing precision
If wire feed speed is controlled independently of welding parameters, then deposition consistency is improved, but system complexity increases
Solution Approach 1:
The controller performs multiple functions: it monitors welding parameters (voltage, current), detects short circuits, controls wire feed speed, and maintains deposition consistency. By consolidating these functions in a single controller, the system achieves independent wire feed speed control without proportionally increasing overall system complexity.
Solution Approach 2:
The system replaces direct mechanical coupling between wire feed control and welding parameter control with an electronic control system. The processor-based controller uses electronic sensing and control to independently manage wire feed speed while responding to welding parameters, reducing mechanical complexity while achieving precise deposition control.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Embodiments of the present invention are directed to systems (100) and a method of controlling wire feeding in a welding operation, where the wire feeding has a plurality of positive and negative pulses. Embodiments determine an average wire feed speed (WFS) and compare the average to a desired wire feed speed and then change a parameter of the wire feed pulses to achieve a desired wire feed speed.