The "breakthrough" of dual wire high-speed welding gun: the wisdom of division of labor and cooperation
The essence of a dual wire high-speed welding gun is "two welding guns combined into one", but it is not simply stacked, but achieves the effect of "1+1> 2" through meticulous collaborative control. The core principle is:
Two welding wires are powered by two independent power sources and are sent out through a common nozzle, but they play different roles in the arc and molten pool:
Pioneer welding wire (main wire):
Task: Undertake the main melting task, use high current to form sufficient melting depth, and lay the foundation for the weld seam.
Role: Like a 'vanguard unit', responsible for opening up the situation and delving deep into the base material.
Follow the welding wire (auxiliary wire):
Task: Fill the weld seam, with the actual effect being the formation of the main weld seam. Usually, a small current or pulse current is used to wet the edges of the weld seam, making its surface smooth and beautiful.
Role: Like a 'logistics and engineering unit', responsible for consolidating positions and leveling land.
This division of labor and collaboration has brought three revolutionary advantages:
1. The "leapfrog" improvement of welding speed
This is a direct contribution. Due to the energy of the heat source being dispersed across two welding wires, the heat input of each wire is precisely controlled while significantly increasing the total heat input. This enables the welding gun to operate stably at speeds 2 to 3 times or even higher than traditional single wire welding. When welding tens of meters long welds on high-speed rail bodies, this speed advantage is multiplied, directly shortening the manufacturing cycle of individual components.
2. Effective protection of welding quality and performance
Relatively low spatter: The dual wire collaborative waveform control technology can cause the arc phases of two welding wires to be staggered and stabilized, thereby reducing the spatter rate to a relatively low level. This means that the weld seam is cleaner, and the workload of subsequent polishing and cleaning is significantly reduced, which itself is another form of "acceleration".
Excellent appearance shaping: Following the "modification" effect of the welding wire, the weld bead is smooth and even, with even and fine fish scale patterns, almost without the need for repair.
Careful heat input control: Although the total energy is high, due to energy dispersion, the thermal impact on the base material is relatively small, reducing workpiece deformation. This is crucial for protecting the dimensional accuracy of large thin-walled structures such as high-speed rail bodies.
3. Optimization of production efficiency in all aspects
One time molding, replacing multi pass welding: For thicker plates, traditional methods require multiple welds (multi-layer multi pass welding). Double wire welding, with its enormous melting ability, often achieves single pass penetration, eliminating the need for repeated slag cleaning and lane changing steps.
Excellent integration with automation equipment: The dual wire high-speed welding gun itself is designed for automated and robotic welding. It is widely integrated into the production line of high-speed rail manufacturing, linked with welding robots and positioners, achieving 24-hour uninterrupted high-quality and high-speed production.