Wire Electrode Feed Control for Precise Welding Stickout
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Solution Overview
Problem
Existing welding apparatuses face challenges in accurately setting and maintaining the free wire electrode length, leading to inaccuracies in welding processes, especially in robotic welding systems where access and automation limitations hinder precise measurement and adjustment.
Innovation Solution
A welding apparatus equipped with a feeding device, wire electrode contact device, reference electrode, and electrical parameter measuring device, which uses voltage or current changes to determine the wire electrode's position and control its feeding to achieve a defined free wire electrode length, allowing for precise setting and adjustment during both manual and automated welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a ruler or gauge is used to measure the free wire electrode length, then the measurement can be performed, but it takes a lot of time and is sometimes not possible due to accessibility issues in robotic welding cells
Solution Approach 1:
The patent replaces the mechanical measurement system (ruler or gauge) with an electrical measurement system. The wire electrode position is determined by measuring electrical parameters (voltage or current) between the wire electrode contact device and reference electrode, eliminating the need for physical measurement tools and manual intervention in difficult-to-reach areas.
Solution Approach 2:
The measurement system is integrated into the welding apparatus itself, allowing the system to automatically determine the wire electrode position without external measurement tools or manual operation. The control device automatically processes electrical parameter measurements to calculate and adjust the free wire electrode length.
2Ease of operation
If manual measurement and adjustment of the wire electrode length is performed, then the free wire electrode length can be set, but personnel must always be available and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated electrical measurement and control system. The control device automatically determines wire electrode position based on electrical parameter measurements and controls the feeding device to achieve the desired free wire electrode length, eliminating the need for manual intervention.
Solution Approach 2:
The system continuously monitors electrical parameters (voltage or current) between the wire electrode contact device and reference electrode, uses this feedback to determine the current wire electrode position, and automatically adjusts the feeding to maintain the correct free wire electrode length.
3Measurement precision
If the wire electrode position is not continuously monitored, then the system operates simpler, but monitoring errors accumulate and the free wire electrode length becomes increasingly inaccurate
Solution Approach 1:
The control device continuously determines the wire electrode position by measuring electrical parameters (voltage or current) between the wire electrode contact device and reference electrode. This continuous feedback mechanism prevents error accumulation by constantly correcting the wire electrode position based on real-time measurements.
Solution Approach 2:
The patent replaces periodic manual measurement with continuous automated electrical monitoring. The electrical parameter measurements provide ongoing feedback on wire electrode position, eliminating the need for intermittent manual checks and preventing drift in the free wire electrode length.
4Extent of automation
If a robotic welding system is used, then automation is improved, but the position of the contact tip end may not be known with sufficient accuracy for precise welding control
Solution Approach 1:
The patent replaces reliance on robotic positioning accuracy with direct electrical measurement of the wire electrode position relative to the contact tip. By measuring electrical parameters between the wire electrode contact device and reference electrode, the system directly determines the free wire electrode length without depending on robotic arm positioning precision.
Solution Approach 2:
The electrical parameter measurement system acts as an intermediary between the robotic positioning system and the welding process control. Instead of relying on the robot's position data, the system uses electrical measurements to directly determine the critical wire electrode position, providing more accurate feedback for welding control.
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 precise and accurate setting of the free wire electrode length, reducing errors and improving welding process control, even in robotic systems, by utilizing electrical parameter measurements to determine and adjust the wire electrode's position efficiently.
Implementation Method 1
an electrical parameter measuring device, in particular a voltage measuring device, which is configured to measure an electrical parameter, in particular a voltage, between the wire electrode contact device and the reference electrode
Data Source
AI summary
The invention provides a welding apparatus and a method for feeding a wire electrode into a position with a defined free wire electrode length from a contact tip of a welding torch of a welding apparatus. Information about a voltage change between the wire electrode on the one hand and a reference electrode on the other hand is used to determine a position of the wire electrode end at the time of the voltage change. The wire electrode can then be moved precisely to the desired position.