Wire Feeder Force Control for Hot Wire Welding Arc Suppression
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Solution Overview
Problem
Current hot wire welding and cladding machines rely on voltage and current feedback to control the resistive heating process, which can lead to arcing issues due to varying wire types, requiring specific parameter settings for each wire type, and are prone to inconsistencies and base metal melting.
Innovation Solution
Employing force feedback from the wire to control the metalworking operation, using sensors and processing circuitry to detect initial contact and adjust heating and feed rate based on force feedback, eliminating the need for specific wire parameter settings by utilizing a controlled start and maintaining constant feed rate through force feedback sensors and processing circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If voltage and current feedback are used to control the resistive heating process, then the wire can be heated to sufficient temperature, but arcing may occur and inconsistencies can arise due to varying wire types
Solution Approach 1:
The patent implements force feedback control by measuring the force exerted on the wire during feeding and using this feedback to adjust heating parameters. This closed-loop control system dynamically adapts to variations in wire properties, maintaining stable heating without arcing by continuously monitoring and responding to actual wire conditions rather than relying on fixed voltage and current settings.
Solution Approach 2:
The system changes the control parameter from voltage and current to force measurement. By measuring the force on the wire and using this as the primary feedback signal, the system can adjust heating parameters dynamically to accommodate different wire types and conditions, resolving the reliability issues caused by wire variation.
2Object-affected harmful factors
If specific parameter settings are made for each wire type to prevent arcing, then arcing can be reduced, but the device complexity increases due to multiple programs
Solution Approach 1:
The system enables itself to adapt to different wire types automatically through force feedback measurement. Rather than requiring external programming for each wire type, the system self-adjusts by measuring the actual force on the wire during operation and dynamically modifying heating parameters, eliminating the need for multiple pre-programmed settings.
Solution Approach 2:
The control parameter shifts from fixed voltage/current settings to dynamic force-based control. This single unified approach replaces multiple wire-type-specific programs, reducing device complexity while maintaining effectiveness in preventing arcing across all wire types.
3Temperature
If high-power energy heating is applied to melt the wire, then the wire reaches plastic state for welding, but electromagnetic pinch forces can cause an arc to be established
Solution Approach 1:
Force feedback measurement allows the system to detect the actual mechanical conditions on the wire in real-time. By monitoring force variations that indicate electromagnetic pinch effects, the system can adjust heating power dynamically to maintain wire temperature in the plastic state while preventing conditions that lead to arcing.
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 significantly reduces arcing and inconsistencies, allowing for precise control of the welding or cladding process across different wire types, maintaining a stable weld or cladding layer without the need for frequent program changes, and preventing excessive base metal melting.
Implementation Method 1
a metal filler wire is heated to a softened or plastic state, usually resistively, by passing an electrical current through it
Implementation Method 2
Employing force feedback from the wire to control the metalworking operation, using sensors and processing circuitry to detect initial contact and adjust heating and feed rate based on force feedback
Data Source
AI summary
A method for controlling a metalworking operation. The method includes measuring a force feedback from a wire being fed from a feeder, the wire contacting a workpiece, determining a change in the force of the force feedback, and adjusting either a heating of the wire or a feed rate of the wire based at least in part on the change in the force of the force feedback. Also disclosed are apparatus for effecting the foregoing.