Professional Documents
Culture Documents
Stava
[56]
4/1977
10/1985
10/1985
1/1988
ABSTRACT
.... 219/130.21
... 219/137 PS
... 219/137 PS
... 219/137 PS
Parks ................................... 219/130
4,020,320
4,544,826
4,546,234
4,717,807
References Cited
3,459,920 8/1969 Sevenco ......
5,001,326
Pijls .................
Nakanishi et al
Ogasawara ......
219/130.51
OTHER PUBLICATIONS
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5,001,326
STVN91S ONVWWOO
XOWECIEEE
U.S. Patent
Sheet 2 of 7
OLTS9.WOcMAI}LWNSOV
1NSOL.IXSVNEA
La
t
10A
29A
SITOA (OMV)
5,001,326
U.S. Patent
Sheet 3 of 7
5,001,326
FIG. 3
190 T5
T2 BREAK P-F
_-PP
IARC
SH
ORT T3 T4
T2TI =3OOps:
500pus
BP+ +IOOpus=TI32OOps
192 T5
VARC
TO T3 T4
EXTENSION VOLTAGE
Vext.
T3 T4
U.S. Patent
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Sheet 4 of 7
5,001,326
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T3
T4
FIG. 5
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U.S. Patent
Sheet 5 of 7
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T3
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79 opeN
AFTER
5.0 SEC, ADJ
o- REF.
--
(SO)
(ALTERATIVE)
-
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FEEDBACK
ACTUAL
(SO)
FIG. 6
CURRENT
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U.S. Patent
Sheet 6 of 7
5,001,326
FIG. 8
PB
3OO
3OOAMP
P-
(DURING PLASMA)
4OO
U.S. Patent
Sheet 7 of 7
5,001,326
FIG. I.
TO
dv/dt (ON)
(TIME)
|= NEW SCHEME
(PINCH)
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15
20
25
30
BACKGROUND
55
65
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15
25
20
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welding procedure, comparing the measured wattage
with the reference wattage to determine an error signal
and using this error signal for controlling the welding
tain level. This switch action is done at a lower current
level and does not cause agitation of the molten metal in current during the plasma boost portion of the welding
the puddle. By providing a maximum time for the 5 cycle so that the plasma boost wattage is controlled at
plasma portion, the plasma portion of the welding cycle the reference wattage by controlling the welding cur
does not have an excessively long decay time, which rent during the plasma boost portion of the welding
could occur if a high time constant were employed in cycle.
Still a further object of the present invention is the
the decay circuit. This aspect of the present invention
gradually reduces the plasma current and maintains a 10 provision of a method and apparatus, as defined above,
quiescent pool to reduce the likelihood of an inadver which method and apparatus involves creating a volt
age spike during the pinch portion of the welding cycle
tent short circuit.
In accordance with another aspect of the present and averaging these voltage spikes to give the voltage
invention, there is provided an arrangement for dealing component for both the reference wattage and the in
with an inadvertent short circuit during the plasma 15 stantaneous wattage. A comparison of signals represent
boost or plasma portion of the welding cycle. It is possi ing these wattages are used to control the welding cur
ble that during the arc condition of the welding cycle a rent during the power boost portion of the cycle.
Another object of the present invention is the provi
short can occur. This short is sensed by an abrupt de
crease in arc voltage, which detection initiates the pinch sion of a method and apparatus, as defined above, which
pulse including its initial delay. Since the metal contact 20 method and apparatus averages the measured extension
is caused by a movement of the puddle to contact the voltage over several cycles for the purpose of creating
electrode, during the initial delay of the pinch cycle, a voltage level representing a reference extension watt
gravity tends to pull the metal away from the electrode. age. This average also creates an continuously updates a
This can cause a reduced metal contact area during this voltage level representing the actual instantaneous
inadvertent short. The metal may be separated quite 25 wattage during the power boost portion of the welding
rapidly by the high current flow to create a fuse before cycle.
Still a further object of the present invention is the
the premonition dv/dt circuit can be initiated at the
normal break point. This could cause severe puddle provision of a method and apparatus, as defined above,
agitation by the break of the premature short. This which method and apparatus controls the wattage di
premature short can occur when a portion of the weld 30 rected to the welding wire during each welding cycle to
puddle rises and contacts the molten metal of the end of control the size of the ball melted at the end of the
the welding wire. Surface tension and gravity then welding wire during each plasma boost portion of the
abruptly pull the shorted, melted mass of metal back welding cycle, regardless of the extension or stick out
into the weld puddle. The surface tension breaks the length of the welding wire.
fuse before the premonition circuit can be activated. 35 Another object of the present invention is the provi
sion of a method and apparatus, as defined above, which
This causes spatter.
In accordance with another aspect of the present method and apparatus substantially increases the ease of
invention, a premature, inadvertent short condition is welding in a spatter control system allowing the opera
detected by an increased voltage. If it is determined that tor to have certain latitude in positioning the holder for
this increased voltage is not a normal short, the break 40 the welding wire during a given welding procedure or
point of the pinch pulse is immediately lowered to a welding run.
Still another object of the present invention is the
substantial current level, such as about 20% of the origi
nal break point current. By reducing the break point provision of method and apparatus for controlling the
current, the pinch pulse shifts to the gradual current welding current level following the plasma boost por
slope as soon as the pinch current increases to the prese 45 tion of a welding cycle for spatter control, which
lected lower level, such as 20% of the normal maximum method and apparatus causes the plasma current after
pinch current. Thus, a longer time is experience before the plasma boost pulse to gradually decrease or decay
separation of the metal and the premonition circuit can from the high plasma boost current level (such as about
become active and allow control of the Darlington 300 amperes) toward the background welding current
switches at the metal fuse to eliminate spatter caused by 50 level (such as about 20 amperes).
Still a further object of the present invention is the
a high current break or fuse.
The primary object of the present invention is the provision of a method and apparatus as defined above,
provision of a method and apparatus for maintaining a which method and apparatus controls the current level
generally constant wattage in the welding wire of a after the plasma boost pulse so that the welding current
welding operation during the plasma boost portion of 55 does not abruptly change from a generally high level
the welding cycle as the extension or stick out distance value to a generally low level value, which abrupt
changes. In accordance with this object, an operator change can cause a certain amount of pool agitation.
Yet a further object of the present invention is the
may manipulate a semi-automatic welder operating in
the short circuiting mode in a manner changing the provision of a method and apparatus, as defined above,
which method and apparatus controls the welding cur
extension distance or stick out of the wire without sub
stantially changing the operating characteristics of a rent level after the power boost portion of the welding
cycle in a manner to control the agitation of the molten
spatter control system.
Yet another object of the present invention is the metal pool immediately after the power boost portion of
provision of a method and apparatus for maintaining a the welding cycle.
generally constant wattage in the wire forming the 65 Yet another object of the present invention is the
extension or stick out of a welding operation by creat provision of a method and apparatus for controlling the
ing an extension reference wattage, measuring the ac break point of a pinch pulse of the welding cycle used in
tual extension wattage at any given time during the spatter control, which method and apparatus detects an
5
current level in an abrupt fashion to terminate the
plasma portion when the melting energy reaches a cer
5,001,326
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7
cuits
to
accomplish
reduced
spatter. The present inven
inadvertent short during the arcing condition and im
mediately shifts the break point of the pinch pulse to a tion relates to an improvement in short circuiting arc
level substantially below the normal 60% break point welding of the type performed by apparatus A with a
current level. In accordance with this object, the pre novel concept performed by a preferred circuit shown
ferred embodiment reduces the break point current to 5 in FIGS. 1 and 2. Apparatus A includes a power supply
approximately 20% of the maximum pinch pulse cur input scheme using various distinct voltage responsive
rent normally experienced in the welding cycle.
current controls for creating separate current portions
Yet another object of the present invention is the of a cycle for short circuiting arc welding, as shown in
provision of an improved spatter control system for a FIG. 4. These control circuits are the voltages applied
short circuiting welding operation, which system may 10 to the command signal lines and the feedback signal
be employed for other welding operations and for the lines and are identified as C1-C7. Welding wire 10 is
purpose of adjusting the stick out or extension in an spaced from workpiece 12 while being supported in an
automatic system, such as a robot control system.
electrical connector or holder 14. Wire 10 can be driven
These and other objects and advantages will become through holder 14 by an appropriate wire feeder 16
apparent from the following description of the present 15 from a supply spool 18 at a rate determined by the oper
invention taken together with the drawings described ator. Holder 14 is connected to one terminal of a D.C.
below:
power supply PS. The amount of wire extending from
BRIEF DESCRIPTION OF DRAWINGS
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cant and will be the same during each pinch pulse PP. In
addition, since this voltage spike measurement is taken
at a precise time on the pinch pulse, immediately after
break point BP, a gradual slope and accuracy is assured.
Referring now to FIG. 5, as the extension or stick out
is changed between those shown as I, II and III, the
measured voltage spikes 200ia, 200b and 200c are corre
spondingly changed. The magnitudes of these voltage
spikes, which have a fixed width x, are measurements of
10 the extension voltage or stick out voltage. The magni
tude increases as the stick out or extension increases.
Thus, the output of switch 130 is a plurality of voltage
pulses or spikes, each representing the extension voltage
during a given welding cycle. A switch 132 operates in
15 unison with switch 130 for a purpose to be described.
The voltage on line 140 is the average of subsequent
voltage spikes 200, as accumulated by an appropriate
voltage averaging device 142, shown as capacitor C1. A
All of the control circuits C1-C7 could be hardwired
circuits; however, in practice, they are provided both second voltage averaging device 150, in the form of
by hardwire and by the output of a microprocessor 20 capacitor C2, receives voltage spikes from switch 132.
which controls the voltage at any given time for the Resistors 160, 162 control the rate of charging for ca
command signals of control circuits C1-C5. The feed pacitor C1, C2, respectively. In practice, capacitors C1,
back signals of circuits C6, C7 are voltages representing C2 are charged to approximately 60% of a peak current
a real time events. Various arrangements could be em during the pinch portion of the welding cycle in ap
ployed for the control circuits without departing from 25 proximately 1620 welding cycles. This charging rate is
schematically illustrated in FIG. 2A. The averaged
the present invention.
Referring now to FIG. 2, the present invention is current for prior voltage spikes 200 appears in line 140.
illustrated wherein the instantaneous arc voltage is ap The instantaneous welding current appears in line 122.
plied to circuit B at line 120. The instantaneous welding These two voltage values are multiplied by a multiply
current is applied to the circuit at line 122. These real 30 ing circuit 170 having an output 172. This output is a
time parameters are measured parameters of the weld voltage representing the extension wattage used as the
ing operation itself. In the microprocessor, there may be control for switch SW6 and form the control circuit C6
provided a circuit B as schematically illustrated in FIG. in FIG. 1. The voltage in line 172 is the product of the
2 or the circuit can be hardwired as shown. Use of a
arc current and the average extension voltage. This
digital circuit or an actual hardwired circuit in accor 35 gives a wattage signal. A sample and hold circuit 180
dance with normal technology does not change the has an output 182 which forms control circuit C3 at the
inventive concepts. Digital switch 130 is closed during input of switch SW3. As so far described, the output
the short time between T3, T4. This short time is imme voltage on line 182 is compared to the voltage on line
diately after the break point BP occurring at time T2 172 when switches SW3, SW6 are activated by logic on
under the control of circuit C1, shown in FIG. 1. After line 194, during a power boost portion of the welding
break point BP, the welding current is controlled along cycle. The welding current is controlled to make these
a more gradual slope 190, best shown in FIG. 3. A values equal at junction 50.
As shown in FIG. 2, a switch 184 schematically rep
measurement of the arc voltage is taken between times
T3, T4 on this more gradual current slope. This selec resents the start-up pulse in line 86. While this switch is
tion of a precise measurement point produces a rela 45 closed, switches 130, 132 charge capacitor C2. After a
tively consistent voltage, since the current at break preselected time at the start of the welding procedure,
point BP is fixed and slope 192 is gradual, as shown in switch 184 opens so that the average extension wattage
FIG. 3. Switch 130 is closed during the period between determined by the voltage in line 182 is a fixed rationet
times T3, T4 which period is a fixed time, such as ap ric voltage against which subsequent wattage measure
proximately 300 microseconds. Time T3 is spaced from 50 ments in line 182 are compared during the power boost
the break point time T2 by a lesser amount time, such as pulse PB.
In operation, during the first 5.0 seconds of the weld
about 100 microseconds. Thus, the voltage between
times T3, T4 is measured during a time of relatively ing procedure, switch SW2 is activated with switch
fixed, known current flow. Thus, the voltage measure SW7. During each pinch pulse PP in the start-up per
ment between these T3, T4 is the extension or stick out 55 iod, a spike 200 is created which measures the actual
voltage for wire 10. This is axiomatic because the mea extension voltage. These spikes are applied to averaging
surement is taken during the pinch pulse PP which is a device 142 (capacitor C1). The average of these spikes
short circuit. All the voltage at line 120 is the voltage in appears in line 140 and is multiplied by the current
the wire between holder 14 and workpiece 12. By tak controlling the voltage on line 122. Thus, the voltage in
ing a voltage spike measurement immediately after line 172 is the voltage level indicative of the product of
break point BP during a gradual current slope at a short the average of the prior spikes 200 and the instantaneous
and for a fixed period of time, the magnitude of the welding current on line 122. Switch 184 is closed; thus,
voltage spike is consistently close to the real time stick switch 132 produces wattage spikes similar to the volt
out or extension voltage. Consequently, as switch 130 is age spikes 200 and occurring at the same time. These
closed between T3, T4 a thin voltage spike 200 is cre 65 wattage spikes from switch 132 are averaged by capaci
ated, such as shown in the bottom portion of FIG. 3. tor C2. A sample and hold device 180 retains the volt
This spike is the extension voltage, since the curve 190 age on capacitor C2 immediately after switch 184 is
for a very short period between times T3, T4 is insignifi opened. In practice, switches 130, 132 are operated in
11
SW6 for controlling the wattage during the power
boost portion or pulse PB of the welding cycle.
During the plasma portion P of the welding cycle, a
logic 0 appears in line 100. At the same time, switch
SW7 is activated to control the current flow between
times T7, T8. A delay circuit, shown schematically and
in hardwired form in FIG. 7, is employed for control
ling the voltage profile of command signal used at con
trol circuit C4. The background current IB after time T8
is controlled by the voltage level at rheostat 102 which
is the command signal of circuit C5. The signal to initi
ate the background current appears on line 104 between
times T8 and T0. At time T0, a logic 0 appears in line
110 to initiate a pinch pulse PP by control of the current
flow between times T0T5 by circuit C1. The voltage
profile of control C1 is shown at the top of FIG. 1 and
it essentially duplicated pulse PP as shown in FIG. 4.
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unison. This produces an accurate correlation between
the voltage spikes 200 directed to capacitor C1 and the
wattage spikes applied to capacitor C2. These spikes are
essentially the same except the level of voltage on ca
45
14
portion P involved an immediate shift from a high level
300 to a low plasma level between level 300 and the
background current. A variety of circuits could be pro
vided for forming the gradual current level decay,
shown as line 302 in FIG. 8. A representative circuit for
this purpose is illustrated in FIG. 7. A switch 310
charges capacitor 320 through resistor 312. The voltage
on line 314 is applied to capacitor 320 by switch 310 and
has a ratio of 1.0 volts per 100 amperes during the
plasma boost pulse PB. This plasma boost current repre
sented by level 300 in FIG. 8 is stored on capacitor 320
during the plasma boost portion of the cycle. After
plasma boost portion of the cycle, switch 310 is deacti
vated. At that time, capacitor 320 is discharged through
rheostat 322. This voltage is amplified by amplifier 330
and appears at line 332 which is the voltage profile of
control circuit C4 shown in FIG. 1 at switch SW4. The
15
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16
neous extension wattage to approach said extension
reference wattage.
3. The improvement as defined in claim 2 wherein
said control signal creating means includes sampling
means for measuring the voltage level across said
holder and said workpiece for a short time and at a
precise time during said short circuit condition and
means for using said measured voltage to create said
control signal.
4. The improvement as defined in claim 3 wherein
said means for using said measured voltage levels in
cludes a voltage accumulator means for adjusting said
control signal toward said measured voltage during
successive shorting conditions.
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12. The improvement as defined in claim 3 including
pinch control means for causing said welding current to
follow a given curve during said short circuit condition
and said sampling means including means for control
ling said precise time as a position on said given curve.
13. The improvement as defined in claim 12 wherein
said extension reference creating means includes means
for activating said reference creating means for a given
time at the start of a given welding procedure, means 10
for controlling the welding current during the plasma
boost portions of successive welding cycles to maintain
a fixed wattage during said plasma boost portions dur
ing said given time, means for storing the product of
said measured voltage levels and said welding current 15
during said given time, and means for using said product
as said extension reference wattage for said given weld
ing procedure.
14. The improvement as defined in claim 13 wherein
pinch control means includes means for causing said 20
welding current to follow a first high slope and then a
second low slope with said slopes intersecting at a break
point and said precise time being immediately after said
break point on said given curve of said welding current
during said short circuit condition.
25
15. The improvement as defined in claim 3 wherein
said short time is less than 500 microseconds.
18
precise location on said given current curve during
said successive short conditions;
(g) averaging said measured voltage levels during
19
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20
plasma boost current pulse at the start of the arcing
condition of successive ones of said welding cycles,
means for maintaining said applied power by control
ling the welding current during said plasma boost cur
rent pulses to provide a predetermined wattage in said
65
control signal.
31. The improvement as defined in claim 30 wherein
said means for using said measured voltage levels in
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point and said precise time being immediately after said
break point on said given curve of said welding current
during said short circuit condition.
38. In a short circuiting arc welding apparatus com
5 prising a D.C. power supply means for causing a weld
ing current of different levels to pass through a welding
wire extending from a holder and between said wire and
a workpiece at a molten metal pool on said workpiece,
wire feeding means for feeding said wire from said
10 holder toward said workpiece whereby said welding
wire is subjected to a succession of welding cycles, each
of said welding cycles including an arcing condition
boost portions of successive welding cycles to maintain during which said wire is spaced from said pool and the
a fixed wattage during said plasma boost portions dur energy applied to said wire exceeds a given value rais
ing said given time, means for storing the product of 15 ing the temperature at the end of said wire to a molten
said measured voltage levels and said welding current temperature to form a molten metal ball on the end of
during said given time, and means for using said product said wire and a short circuit condition during which
as said extension reference wattage for said given weld said molten metal ball on the end of said wire first
ing procedure.
contacts said molten metal pool and then transfers from
35. The improvement as defined in claim 30 including 20 said wire to said workpiece by a necking action break
pinch control means for causing said welding current to ing said molten metal ball from said wire to initiate an
follow a given curve during said short circuit condition, arc in a subsequent welding cycle, the improvement
and said sampling means including means for control comprising: means for creating a current pulse upon
ling said precise time as a position on said given curve. initiation of said arcing condition, said current pulse
36. The improvement as defined in claim 35 wherein 25 having a first occurring plasma boost portion with a
said extension reference creating means includes means current increasing to a first general current level and a
for activating said reference creating means for a given second occurring plasma portion with a second general
time at the start of a given welding procedure, means current level, said first general current level being at a
for controlling the welding current during the plasma controlled high current level and said second general
boost portions of successive welding cycles to maintain 30 current level decreasing gradually from said controlled
a fixed wattage during said plasma boost portions dur high current level.
21
33. The improvement as defined in claim 32 wherein
pinch control means includes means for causing said
welding current to follow a first high slope and then a
second low slope with said slopes intersecting at a break
point and said precise time being immediately after said
break point on said given curve of said welding current
during said short circuit condition.
34. The improvement as defined in claim 30 wherein
said extension reference creating means includes means
for activating said reference creating means for a given
time at the start of a given welding procedure, means
for controlling the welding current during the plasma
35
40
45
50
55
65