Doc.

XII-2214-15
IV-1231-15
212-1358-15

Study on Metal Transfer Control

Using Synchronous Control of Wire
Feeding and Current Waveform
- Intermediate Report -

Welding Products Div. & Mechatronics Div.

○T.ERA, A.IDE,
S.MIZUURA, H.MIYAHARA and S.Hirota
 Contents
1. Background
2. System Configuration
3. Principle of New Process
4. Features and Effect of New Process
5. Applications
6. Summary

DAIHEN Corporation Doc.XII-2214-15 - 1 -

 Mission to Development

To realize a ultra low spatter & high

speed welding process with sufficient
penetration in the globular transfer
mode up to 300A on CO2 and MAG
welding process,
using synchronous control of wire
feeding and current waveform.

DAIHEN Corporation Doc.XII-2214-15 - 2 -

 Pioneer of Mechanical Metal Transfer Control in Japan

Low Inertia Motor Yamamoto et al. : Preprint of the

-Vr
National Meeting of JWS in 1973
Tachometer O
Repeat
+Vf

Inching Retract

Motor Drive Circuit

DC Power Supply
(Const. Current)

+Ef

Shmit Trigger
Ea Arc Short
Ta O cricuit
Ts -Er
40 Short circuit

E (Volt)
Arc
30
20
10
0 10 20 30 40
Time (msec)
Vf (m/sec)
0.3
0.2
0.1
0
-0.1 10 20 30 40
-0.2

6
L (mm)

4
The Golden Electrode Halil Kaya Gedik Award 2
from IIW in 2013 0
10 20 30 40
DAIHEN Corporation Doc.XII-2214-15 - 3 -
 Mission one to overcome

Rate (cm/min.) Feed Direction Short-Circuit / Arc

Arc Arc Arc

+ + +
- - -
Mean Wire Feed

Target of mean
wire feed rate
Time (s)

Wire feed direction changes according to the arc phenomena (arc / short-circuit)
Since the metal transfer in the globular transfer mode is not so stable,
the mean wire feed rate is not constant.
Therefore it’s difficult to regulate the arc length using CV characteristic of WPS.

DAIHEN Corporation Doc.XII-2214-15 - 4 -

 Mission two to overcome
Retracted wire zone, Metal Transfer Control
which was already with Wire Feeding

Wire melt rate (cm/min)

heated. Doubly heated zone
by inching control
of the wire
Contact
Tip
Heating Normal GMA
point welding process
Wire

Base Metal Welding current (A)

As shown in figure above, the wire extension from

the contact tip is doubly heated.
Therefore the wire melt rate gets higher
than the normal GMA welding process,
that is a low heat input into the base metal. Shallow penetration
150A by CO2 shielded
conventional low spatter process
DAIHEN Corporation Doc.XII-2214-15 - 5 -
 Contents
1. Background
2. System Configuration
3. Principle of New Process
4. Features and Effect of New Process
5. Applications
6. Summary

DAIHEN Corporation Doc.XII-2214-15 - 6 -

 System Configuration
No. Component New②
① Pull Feeder
② Push Feeder
③ Wire Buffer New④
④ Feeder Controller
New③

New①

DAIHEN Corporation Doc.XII-2214-15 - 7 -

 Control Diagram
Push Wire Pull
Feeder Buffer Feeder

Torch
Wire
Reel 2-Axeses
AC Servo
Driver
High Speed Serial
Communication BUS
Welding Encoder Signal
Robot
Power Feed Signal
Controller
Source Encoder Signal

DAIHEN Corporation Doc.XII-2214-15 - 8 -

 Contents
1. Background
2. System Configuration
3. Principle of New Process
I. Buffer Position Control
II. Pulsed Dip Transfer Process
4. Features and Effect of New Process
5. Application
6. Summary

DAIHEN Corporation Doc.XII-2214-15 - 9 -

 Buffer Position Control
Feed Roll Feed Roll
at Push Motor at Pull Motor
S-Shaped Buffer

Digital encoder position (angle) signal

Servo Driver
Push feeder
Constant Wire Feed Rate
Pull feeder
Feed Direction Control &
Mean wire feed rate control

DAIHEN Corporation Doc.XII-2214-15 - 10 -

 BP control sample
Buffer position
Wire Feed Rate at Push Feeder
= Mean Wire Feed Rate at Pull Feeder

Convergence to center position

Center of buffer position

Current (A)

Weld Start Time (s)

DAIHEN Corporation Doc.XII-2214-15 - 11 -

 Effect of BP control
1. Compensation of the mean wire feed
rate.
This helps arc length regulation in the
globular transfer mode, by using CV
characteristic of WPS.

Easy operation to make a welding condition

like conventional GMA processes.

2. Avoiding from troubles of the wire

feed system.

DAIHEN Corporation Doc.XII-2214-15 - 12 -

 Contents
1. Background
2. System Configuration
3. Principle of New Process
I. Buffer Position Control
II. Pulsed Dip Transfer Process
4. Features and Effect of New Process
5. Application
6. Summary

DAIHEN Corporation Doc.XII-2214-15 - 13 -

 Pulsed Dip Transfer Process
Current control Pulsed current control
during short- during arc duration
circuit duration with CV regulation,
Current(A)

that realizes deep

penetration.
Wire feed rate (m/min)

Time (s)

Inching
Retract Time (s)

(a (b) (c) (d)

DAIHEN Corporation
) Doc.XII-2214-15 - 14 -
 Arc Phenomena of PDT process for CO2

Mean Wire Feed Rate : 10m/min., Short-circuit/Arc Frequency : 100Hz

Mean Current 300A, Travel Speed 100cm/min.

DAIHEN Corporation Doc.XII-2214-15 - 15 -

 Contents
1. Background
2. System Configuration
3. Principle of New Process
I. Buffer Position Control
II. Pulsed Dip Transfer Process
4. Features and Effect of New Process
5. Applications
6. Summary

DAIHEN Corporation Doc.XII-2214-15 - 16 -

 Wire melt characteristic
14.00
Developped MAG
12.00 Developped CO2
Conventional MAG
Wire melt rate (m/min)

Conventioanl CO2
10.00

8.00

6.00

4.00

2.00

0.00
0 100 200 300
Wire size 1.2 mm Current (A)

DAIHEN Corporation Doc.XII-2214-15 - 17 -

 Spatter Generation Level

0.15
Developped MAG
Spatter generation level (g/min)

0.13 Developped CO2

Conventional MAG
Conventioanl CO2
0.10

0.08

0.05

0.03

0.00
50 150 250 350
Current (A)

DAIHEN Corporation Doc.XII-2214-15 - 18 -

 Contents
1. Background
2. System Configuration
3. Principle of New Process
I. Buffer Position Control
II. Pulsed Dip Transfer Process
4. Features and Effect of New Process
5. Applications
6. Summary

DAIHEN Corporation Doc.XII-2214-15 - 19 -

 Application Samples
Bead appearance Cross section
3.2mm
Lap joint
300A
22.5V
100cm/min

3.2mm
T-fillet joint
250A
23.0V
50cm/min

DAIHEN Corporation Doc.XII-2214-15 - 20 -

 Application Samples
Bead appearance Cross section
0.6 mm
Butt joint
50A
18.0V
70 cm/min
0.6 mm
Lap joint
0.6mm gap
50A
18.0V
70cm/min

DAIHEN Corporation Doc.XII-2214-15 - 21 -

 Application Samples
100%CO2, 100%CO2,
SPCC 1.0mmt SPCC 3.2mmt
80A(1.7m/min), 17V 130A(3.2m/min), 17V
45cm/min, W.F. 5Hz 45cm/min, W.F. 4Hz

DAIHEN Corporation Doc.XII-2214-15 - 22 -

 Summary
1. New Metal Transfer Control Using
Synchronous Control of Wire Feeding and
Current Waveform has been developed.

2. Buffer Position Control can compensate

the mean wire feed rate, which helps arc
length regulation in the globular transfer
mode using CV characteristic of WPS, and
avoid from troubles on the wire feed
system.

3. Pulsed Dip Transfer Process can realize

ultra low spatter with sufficient
penetration and high speed welding.

DAIHEN Corporation Doc.XII-2214-15 - 23 -

 Thank you for your attention!!

WHAT A WONDERFUL WELDING

DAIHEN Corporation