Integrated systems for submerged arc welding
Digital arc control unit:
Two types of digital arc control unit are available, distinguished by the number of filler metals:
The integrated regulator for current and voltage is equipped with a sophisticated control loop, thus making it possible to limit the amount of heat input into the joint. The digital logging of actual weld values featuring high sampling rates guarantees an accurate acquisition of current and voltage, independent of the respective wave pattern.
Parameters are constantly being adjusted throughout the whole welding sequence. The integrated control employs pre-set values to establish both the current and voltage characteristics in the inital and the final joining phase. The two-stage control release improves starting of the arc, especially without contact between wire and base material. The adaptive control limitation will be activated if any trouble occurs.
Another feature is the digital wire feed control ensuring the defined burn-off, and further handling the withdrawal at the end of operation. Automatic limitation of the wire feed prevents the occurrence of short circuits after short interruptions.
- single-wire method and
- multiple SAW.
The integrated regulator for current and voltage is equipped with a sophisticated control loop, thus making it possible to limit the amount of heat input into the joint. The digital logging of actual weld values featuring high sampling rates guarantees an accurate acquisition of current and voltage, independent of the respective wave pattern.
Parameters are constantly being adjusted throughout the whole welding sequence. The integrated control employs pre-set values to establish both the current and voltage characteristics in the inital and the final joining phase. The two-stage control release improves starting of the arc, especially without contact between wire and base material. The adaptive control limitation will be activated if any trouble occurs.
Another feature is the digital wire feed control ensuring the defined burn-off, and further handling the withdrawal at the end of operation. Automatic limitation of the wire feed prevents the occurrence of short circuits after short interruptions.
Multiple SAW system (schematic)
This solution is also available for multiple SAW. All filler metals are addressed by one single controller, thus improving the quality of the weld. The simultaneous data logging not only reduces maintenance work, but also helps to detect trouble with earth connection.
At the start and end of operation, powering/unpowering of the wires is done sequentially. A controller limitation will be effective with the front wires, if problems occur. Cold wire is fed electrically coupled. This positively influences deposit efficiency, the consumption of powder and energy, heat input and HAZ.
At the start and end of operation, powering/unpowering of the wires is done sequentially. A controller limitation will be effective with the front wires, if problems occur. Cold wire is fed electrically coupled. This positively influences deposit efficiency, the consumption of powder and energy, heat input and HAZ.
Welding head
The user will appreciate the integrative welding schedule involving all wires, representing a simplified presetting of sequential start and stop, adjusted current characteristics, as well as an adaptation to welding speed. With multiple SAW, control accuracy is within ±1 V and ±10 A, resp., and the measurement error is lower than 0.5 %.
Featuring permanent monitoring of the welding operation as well as transfer of the measured data to the central visualisation, unattended welding becomes possible. This work load relief allows the allocation of several machines to one operator.
Process data logging and the consistent trouble-shooting system provide valuable support in proving quality. Continuous storage of all relevant information on a central server allows the generation of many statistical reports: it is, amongst others, possible to document the position of welding defects and to ascribe the amount of consumables to the resp. order. Information about trouble shooting is further available to maintenance personnel.
Featuring permanent monitoring of the welding operation as well as transfer of the measured data to the central visualisation, unattended welding becomes possible. This work load relief allows the allocation of several machines to one operator.
Process data logging and the consistent trouble-shooting system provide valuable support in proving quality. Continuous storage of all relevant information on a central server allows the generation of many statistical reports: it is, amongst others, possible to document the position of welding defects and to ascribe the amount of consumables to the resp. order. Information about trouble shooting is further available to maintenance personnel.
Read this application report:
Combined Arc Control and Seam Tracking system for SAW Welding for ESAB (1470kB)
Combined Arc Control and Seam Tracking system for SAW Welding for ESAB (1470kB) 
