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Automatic welding method and apparatus

  • US 10,166,622 B2
  • Filed: 12/15/2010
  • Issued: 01/01/2019
  • Est. Priority Date: 12/16/2009
  • Status: Active Grant
First Claim
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1. A method of automatically controlling welding using a welding apparatus, the method comprising the following steps:

  • providing a heat-source that generates a welding-arc;

    providing a wire feed for feeding wire to a wire interaction position, the wire interaction position being a position where the wire feed interacts with the welding-arc; and

    providing a control system comprising;

    a pre-programmed robot control system, a control system interface, and a camera configured to record the wire interaction position and communicate the recording to the control system interface, wherein the control system is configured to;

    set at least one welding parameter having an adjustable magnitude and direction;

    set a stable wire interaction position with a defined tolerance, the stable wire interaction position being a position where the wire fed by the wire feed interacts with the welding-arc so as to produce a weld having pre-defined qualities;

    define a number of zones with respect to the stable wire interaction position, a first zone being defined based on a diameter of the wire;

    monitor whether the wire interaction position deviates from the defined tolerance of the stable wire interaction position during welding;

    determine which zone the wire interaction position is located in;

    automatically alter the magnitude and direction of the at least one welding parameter to return the wire interaction position to within the defined tolerance of the stable wire interaction position if the wire interaction position deviates from the defined tolerance of the stable wire interaction position during welding, wherein the alteration of the magnitude and direction of the at least one welding parameter is dependent on which of the number of defined zones the wire interaction position is located in, and the at least one welding parameter comprises at least a wire feed rate adjusted in accordance with a pre-programmed algorithm based on which of the number of defined zones the wire interaction position is located in.

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