ADAPTABLE ROTATING ARC WELDING METHOD AND SYSTEM

• US 20140027422A1
• Filed: 02/14/2013
• Published: 01/30/2014
• Est. Priority Date: 07/27/2012
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Panelli, Edward J.
• Granted Patent: US 9,511,442 B2
• Time in Patent Office: Days
• US Class Current: 219/125.1
• CPC Class Codes: B23K 31/003 relating to controlling of welding distortion
• CPC Class Codes: B23K 9/0216 Seam profiling, e.g. weaving, multilayer
• CPC Class Codes: B23K 9/095 Monitoring or automatic control of welding parameters
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/173 and of a consumable electrode

Abstract

A welding operation is performed utilizing a rotating arc resulting from movement of a welding electrode in a welding torch. Workpiece fit-up is determined as the weld progresses, such as via a camera and image analysis. In the event that fit-up changes, such as by the development of gaps between the workpieces, one or more parameters of the system may be altered, such as the geometry of the electrode movement, the travel speed, the wire feed speed, the weld power applied to the electrode, and so forth. The technique may be automated, such as for accommodating welding via welding robots.

Claims

1. A welding method comprising:

establishing an arc between a welding electrode and a workpiece;

feeding the electrode from a welding torch while cyclically moving the electrode in a desired pattern by a motion control assembly within the welding torch;

advancing the welding torch or the workpiece to establish a weld bead; and

altering a geometry of the desired pattern while maintaining the arc and weld bead.

2. The welding method of claim 1, wherein altering the geometry of the desired pattern comprises altering a diameter of a generally circular pattern.

3. The welding method of claim 1, comprising also altering a wire feed speed of the electrode.

4. The welding method of claim 1, comprising also altering a travel speed of the welding torch.

5. The welding method of claim 1, comprising also altering a parameter of weld power applied to the electrode.

6. The welding method of claim 1, comprising detecting a fit-up parameter of the workpiece, and wherein the geometry of the desired pattern is altered based upon the detected fit-up.

7. The welding method of claim 6, wherein the fit-up parameter is detected by a detector mounted to the welding torch.

8. The welding method of claim 1, wherein the welding torch is mounted to a welding robot.

9. A welding method comprising:

establishing an arc between a welding electrode and a workpiece;

feeding the electrode from a welding torch while cyclically moving the electrode in a desired pattern by a motion control assembly within the welding torch;

advancing the welding torch or the workpiece to establish a weld bead;

detecting a fit-up parameter of the workpiece; and

altering a geometry of the desired pattern based upon the detected fit-up parameter while maintaining the arc and weld bead.

10. The welding method of claim 9, wherein altering the geometry of the desired pattern comprises altering a diameter of a generally circular pattern.

11. The welding method of claim 9, comprising also altering a wire feed speed of the electrode based upon the detected fit-up parameter.

12. The welding method of claim 9, comprising also altering a travel speed of the welding torch based upon the detected fit-up parameter.

13. The welding method of claim 9, comprising also altering a parameter of weld power applied to the electrode based upon the detected fit-up parameter.

14. A welding method comprising:

establishing an arc between a welding electrode and a workpiece;

feeding the electrode from a welding torch while cyclically moving the electrode in a desired pattern by a motion control assembly within the welding torch;

advancing the welding torch or the workpiece to establish a weld bead; and

altering at least one of a geometry of the desired pattern, a welding torch travel speed, an electrode wire feed speed, a parameter of welding power applied to the electrode, and a rate of cyclic movement of the electrode while maintaining the arc and weld bead.

15. The welding method of claim 14, comprising detecting a fit-up parameter of the workpiece, and wherein the alteration is based upon the detected fit-up.

16. The welding method of claim 15, wherein the fit-up parameter is detected by a detector mounted to the welding torch.

17. A welding system comprising:

a power supply configured to generate welding power;

a welding torch configured to receive the welding power;

a wire feeder configured to feed welding wire to the welding torch;

a welding wire rotation assembly associated with the welding torch and configured to move the welding wire as the welding wire is advanced towards a work piece and as an arc is maintained by the welding power;

a fit-up parameter detection component configured to detect a fit-up parameter of the workpiece; and

control circuitry configured to alter movement of the welding wire based upon the fit-up parameter.

18. The welding system of claim 17, wherein movement of the welding torch is controlled by a welding robot on which the welding torch is mounted.

19. The welding system of claim 17, wherein the fit-up parameter detection component is mounted to the welding torch.

20. The welding system of claim 17, wherein the control circuitry comprises circuitry of at least one of the power supply and the wire feeder.