Wire Pulser Mechanism for High Deposition GTAW Welding
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Solution Overview
Problem
Existing portable GTAW welding systems face limitations in deposition rate and efficiency, particularly in achieving high wire feed consumption rates without increasing complexity or vibration in portable equipment.
Innovation Solution
A welding apparatus incorporating a wire pulser with an internal slider crank mechanism that oscillates the wire conduit length to pulse the welding wire, allowing for increased deposition rates while minimizing vibrations and enabling quick conduit changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire feed speed is increased to achieve higher deposition rates, then productivity improves, but vibration and equipment complexity increase
Solution Approach 1:
The patent implements a pulsed wire feed mechanism that periodically accelerates and decelerates the wire in a controlled manner. This periodic action creates a pulsing effect that increases deposition rate while the controlled acceleration/deceleration profile minimizes harmful vibrations compared to continuous high-speed feeding
Solution Approach 2:
The wire feed system transitions from static constant speed feeding to dynamic pulsed feeding with variable speed profiles. The system dynamically adjusts wire feed speed within each pulse cycle, allowing optimization of deposition rate while controlling vibration through programmed acceleration and deceleration phases
2Productivity
If wire feed speed is increased to achieve higher deposition rates, then productivity improves, but device complexity increases
Solution Approach 1:
The pulsed wire feed mechanism is integrated into the existing wire feed drive system, combining the pulsing function with the conventional wire feeding mechanism. This merging approach achieves high deposition rates without requiring entirely separate complex equipment, as the pulsed action is implemented through modification of the existing wire feed system
3Object-affected harmful factors
If wire conduit length is increased to reduce vibration, then harmful factors decrease, but wire feed time increases
Solution Approach 1:
Rather than increasing conduit length, the patent uses periodic pulsing of the wire feed to address vibration. The pulsed delivery creates controlled motion that reduces vibration harmful effects while maintaining short conduit lengths, thereby avoiding the time loss associated with longer wire paths
Data Source
AI summary
A welding apparatus is provided herein. The apparatus includes a wire source having welding wire, a wire feed drive, and a wire pulser. The wire feed drive drives the welding wire from the wire source. The wire pulser has a first end associated with the wire feed drive and a second end associated with a wire conduit. The wire is fed through the wire conduit to a wire nozzle. The wire pulser increase and decrease the effective length of the wire as the wire moves through the wire conduit from the wire feed drive to the wire nozzle.