Wire-Feed Additive Manufacturing Control for Weld Bead Height
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Solution Overview
Problem
Existing additively manufacturing methods face challenges in accurately managing the height of weld layers due to variations in welding conditions, leading to shape errors in the final product, as the control system often assumes a constant filler metal supply speed, which can differ from the actual speed.
Innovation Solution
The method involves measuring the filler metal feed speed, acquiring a reference welding speed, measuring the weld bead height, calculating a welding speed correction value based on the height difference, and adjusting the welding speed to form the weld bead accurately, ensuring precise control over the weld layer height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the control system assumes a constant filler metal supply speed, then the control is simplified, but the actual welding speed varies causing shape errors
Solution Approach 1:
The patent implements feedback control by measuring the actual filler metal supply speed and using this information to adjust the welding torch speed. The control system continuously monitors the filler metal feed speed and modifies the welding parameters accordingly, creating a closed-loop control system that maintains accurate weld bead height despite variations in filler metal supply conditions.
2Manufacturing precision
If the welding speed is adjusted to compensate for filler metal feed speed variations, then the weld bead height accuracy is improved, but the control system complexity increases
Solution Approach 1:
The control system uses feedback from filler metal feed speed measurements to dynamically adjust welding parameters. The measured filler metal feed speed is fed back to the control system, which then calculates and applies appropriate corrections to the welding torch speed, creating an automated closed-loop control that manages complexity while maintaining precision.
Solution Approach 2:
The patent changes welding parameters (specifically welding torch speed) based on measured filler metal feed speed variations. By dynamically adjusting these parameters in response to actual conditions, the system maintains weld quality without requiring overly complex control mechanisms.
3Manufacturing precision
If the filler metal feed speed is measured and used to adjust welding speed, then the shape error is reduced, but the measurement and control complexity increases
Solution Approach 1:
The system measures the actual filler metal feed speed and uses this information in a feedback loop to adjust the welding torch speed. This feedback mechanism enables the system to compensate for variations in filler metal supply, reducing shape errors in the additively manufactured object while managing the complexity through automated control.
Solution Approach 2:
The patent replaces manual or open-loop mechanical control with an automated control system that uses electrical sensors and actuators. By substituting mechanical adjustment methods with electronic measurement and control, the system achieves more precise control with manageable complexity.
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 allows for accurate management of the filler metal feed speed and weld bead height, resulting in high-accuracy additively manufactured objects by compensating for variations in welding conditions and ensuring the correct welding speed is maintained.
Implementation Method 1
uses a heat source such as laser beams, electron beams, and arcs to melt a metal powder or a metal wire
Implementation Method 2
melt a metal powder or a metal wire, and deposits the molten metal to create an additively manufactured object
Data Source
AI summary
An additively manufacturing method includes: measuring a filler metal feed speed at which the filler metal is fed to the welding torch during the formation of the weld bead; acquiring a reference welding speed that is a moving speed of the welding torch corresponding to the measured filler metal feed speed; measuring a height of the formed weld bead; acquiring a welding speed correction value with which the height of the weld bead to be formed is adjusted based on a difference between the measured height of the weld bead and a height of a tip of the filler metal that protrudes from the tip of the welding torch; correcting the reference welding speed with the welding speed correction value and determining a welding speed at which the weld bead is formed; and forming the weld bead at the determined welding speed.