Method of igniting arcs

Abstract: A method of igniting arcs wherein an electric field is formed in the vicinity of an electrode and ignition-plasma is projected against a cathode in the electric field, to thereby ignite an arc.

Description: BACKGROUND OF THE INVENTION (1) FIELD OF THE INVENTION This invention relates to a method of igniting arcs which is suitable for use in producing an electric discharge between at least one main discharging electrode and a workpiece or another electrode to perform, by the heat generated by the electric discharge, a welding, cutting, metallization or heating operation on the workpiece. (2) DESCRIPTION OF THE PRIOR ART Heretofore, several methods have been available to produce an arc discharge. One of such methods is a high-frequency arc igniting method wherein a high-frequency high voltage is impressed between a main discharging electrode and a workpiece or another electrode to produce an arc discharge between them by causing a dielectric breakdown to occur. Another method is a contact arc igniting method wherein a main discharging electrode is brought into contact with a workpiece to produce a spark by contact and then the main discharging electrode is moved away from the workpiece to convert the spark discharge caused by contact into an arc discharge which is used for performing a desired operation on the workpiece. Some problems are encountered in these methods of the prior art. In the high-frequency arc igniting method, the high-frequency voltage used for producing an arc is so high that an electromagnetic noise of high magnitude is produced, with a result that a microcomputer or other peripheral electronic devices incorporated in an automatic welding machine might misoperate or suffer damage. This has made it necessary to use a special noise filter to cope with the high frequency noise of high magnitude. Also, measuring equipment coupled to the arc generating circuit might suffer damage when an arc is ignited by using a high-frequency high voltage, making it impossible to readily couple the measuring equipment to the welding electric circuit. Particularly when an alternating current is used for performing welding, it is necessary to impress a high-frequency high voltage to reignite an arc for each A.C. half-wave, so that the incidence of production of a high-frequency noise of high magnitude is high. In the contact arc igniting method, one may fail in igniting an arc depending on the shape of the forward end of the main discharging electrode and the condition of the surface of the workpiece. When welding is performed by using an alternating current, the stability of the arc may be impaired due to arc extinction which might occur when one half-wave of A.C. is switched to the other half-wave. Reigniting an arc for each half-wave of A.C. is impossible to perform by the contact arc igniting method. GB-A-2 092 933 discloses a method of manufacturing a lamp in which a lamp assembly has an external lead-in wire having an outer end which is drawn out between the lamp bulb and the lamp base, a potential is applied between a welding electrode and a tip of the external lead-in wire, and a gas flame is interposed between the outer end of the external lead-in wire and the welding electrode. A D.C. power unit has the positive terminal grounded and the negative terminal connected to the welding electrode through the secondary winding of a step-up transformer to the primary of which a high frequency generator is connected. The lamp assembly is mounted with its base connected to ground by a holder of conductive material. The gas flame, from combustion of coal gas, serves to facilitate the arc discharge. SUMMARY OF THE INVENTION This invention has as its object the provision of a method of igniting an arc which is capable of readily igniting an arc of high stability without substantially producing a high-frequency noise of high magnitude. This object is achieved by the method of claim 1. In the method according to the invention, the main electrode serves as a cathode. Stated differently, the polarity is straight. DESCRIPTION OF THE INVENTION (1) GENERAL PRINCIPLES Fig. 5 shows a straight polarity arrangement in which an electrode is positioned to face a workpiece, and a direct current power source for producing an arc has the electrode connected to its negative terminal and the workpiece connected to its positive terminal. A perforated electrode is positioned to face the side of the electrode and grounded together with the workpiece, so as to create an electric field oriented from the perforated electrode toward the electrode to introduce ignition-plasma into the electrode through a hole in the perforated electrode, as indicated at 1 ○ in the figure. This produces a cathode spot on the electrode to allow an arc to be ignited from the electrode to the perforated electrode, as indicated at 2 ○ in the figure. Then, the cathode spot shifts to the forward end of the electrode, as indicated at 3 ○ in the figure, depending on a flow of shield gas (Qs) and/or the shape of the electric field. Thus, an arc is ignited, as indicated at 4 ○ in the figure, between the electrode and the workpiece. Influences exerted by the electric field on the shifting of the cathode spot will be described. Figs. 6a and 6b show one example of the relation between the geometrical arrangement of the workpiece, electrode and perforated electrode and the presence or absence of an arc ignited between the electrode and the workpiece, electrode and perforated electrode and the presence or absence of an arc ignited between the electrode and the workpiece. As seen in Fig. 6, the arc ignited is greatly influenced by the position of the perforated electrode. In the figure, marks x, o, ▵ and □ indicate that no arc is ignited, an arc is ignited (the arc indicated at 2 ○ shifts quickly to the arc indicated at 4 ○ in Fig. 5 within one second), the arc ignited shifts from 2 ○ to 4 ○ in Fig. 5 slowly and the arc indicated at 2 ○ in Fig. 5 does not shift to the arc indicated at 4 ○ in Fig. 5 respectively. It is the shape of the electric field in the vicinity of the electrode, workpiece and perforated electrode that shows a change as shown in Fig. 6b depending on the position of the workpiece, the electrode and the grunded perforated electrode. It would be considered that the deformation of the electric field causes the cathode spot to shift. With regard to a plasma projector used for igniting an arc, when it is used for igniting an arc at high frequencies (Fig. 2b), the high-frequency voltage impressed between the electrode of plasma projector 13 (hereinafter referred to as a subelectrode) and the nozzle member of plasma projector 13 is relatively low, and a noise of high magnitude that has hitherto been produced when a high-frequency current of high voltage was applied directly to the main discharging electrode is not produced. When an ignition-plasma is ignited by contact arc igniting (Fig. 2a), ignition-plasma is produced by bringing the subelectrode 12 into contact with the nozzle member of the plasma projector 13 and then moving them away from each other. Since the plasma is a small current of about 10 A, a waste of the subelectrode 12 is negligible. When the plasma projector is used for igniting an arc by using a self-exothermic electrode (Fig. 2c), a non-consumable electrode having at least two terminals is used, and a current is passed through the terminals to cause the subelectrode to generate heat to produce ignition-plasma. When the plasma projector is used for igniting an arc by the aforesaid processes, electronic equipment in the Vicinity of the torch is prevented from misoperating or suffering damage. Measuring equipment can be directly coupled to the welding electric circuit. When an arc is ignited by a contactless process, the problem encountered in the prior art that, when an arc is ignited by using a non-consumable electrode for working on metals, the tungsten electrode is consumed can be obviated. Thus, the present invention would have high industrial value. (2) BRIEF DESCRIPTION OF THE DRAWINGS Ways of carrying out the invention will now be described, by way of example only, with reference to Figures 1c, 1d, 2a, 2b, 2c, 3a, 3b and 4 of the accompanying drawings, in which: Figs. 1a-1d are vertical sectional views of arc welding systems, the systems of Figs. 1c and 1d being suitable for carrying the method according to the invention into practice; Fig. 2a is a block diagram of the ignition-plasma generating circuit used when the plasma projectors are of the contact arc igniting type; Fig. 2b is a block diagram of the ignition-plasma generating circuit used when the plasma projectors are of the high-frequency arc igniting type; Fig. 2c is a block diagram of the ignition-plasma generating circuit used when the plasma projectors are of the self-exothermic electrode arc igniting type; Figs. 3a and 3b are fragmentary sectional views showing in detail the manner in which the plasma projectors shown in Figs. 1a and 1b are mounted; Fig. 4 is a vertical sectional view of the plasma projector according to the invention, showing its construction in detail; Fig. 5 is a block diagram showing the shifting of the cathode spot; and Figs. 6a and 6b are views in explanation of the shifting in the cathode spot and the formation of an electric field in relation to the geometrical arrangement of the electrode, workpiece and perforated electrode. DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the invention will now be described in detail by referring to Figures 1c, 1d, 2a, 2b, 2c, 3a, 3b, and 4 the accompanying drawings in which various embodiments and examples of systems suitable for carrying the method according to the invention into practice are shown. The arc welding systems of Figures 1a and 1b will be described as background information to the systems of Figures 1c and 1d respectively. (1) Operation Performed with an A.C. Arc using a Non-Consumable Electrode (background to Figure 1c) Fig. 1a shows an A.C. arc welding torch of the non-consumable electrode type. As shown, the numeral 1 designates an A.C. arc welding power source which has a doping characteristic. The arc welding power source 1 has two A.C. output terminals, one of the A.C. output terminals being connected to a tungsten electrode 2 (main discharging electrode, hereinafter referred to as a main electrode) located in a welding torch 7 and the other A.C. output terminal being connected to a workpiece 3 to be welded. The welding power source 1. main electrode 2 and workpiece 3 constitute a welding electric circuit 8. A plasma projector 13 for igniting an arc is located in the vicinity of the main electrode 2 and has an subelectrode 12 which is connected to the cathode of an ignition-plasma device 10 and a nozzle member which is connected to the anode of the ignition-plasma device 10. The ignition-plasma device 10, the subelectrode and the nozzle member of the plasma projector 13 constitute an ignition-plasma generating circuit 18. The nozzle member of the plasma projector 13 is connected to the workpiece 3. Fig. 2a shows in a block diagram an ignition-plasma generating circuit 18 (25) of the contact arc igniting type. The numeral 11 designates a plasma power source having a D.C. drooping characteristic. The plasma power source 11 has the subelectrode 12 connected to its cathode and the nozzle member of the plasma projector 13 connected to its anode. The plasma power source 11, subelectrode 12 and the nozzle member of the plasma projector 13 constitute an ignition-plasma generating circuit. To produce an ignition-plasma by using the ignition-plasma generating circuit of the aforesaid construction, plasma power source 11 is turned on to impress a no-load voltage between the subelectrode 12 and the nozzle member of the plasma projector 13. While being in this condition, the subelectrode 12 is brought into contact with the nozzle member of the plasma projector 13 manually, electrically or by using known means, such as a bimetal strip or a spring, to cause a short-circuit to take place. After a transient current is passed by the short-circuiting, the subelectrode 12 is moved away from the nozzle member of the plasma projector 13 to generate an ignition-plasma. In the contact arc igniting process of the prior art (the process for igniting a main welding arc), the problem that an excessively large current produced by short-circuiting brings about a waste of the forward end portion of the main electrode was encountered. The current used to generate an ignition-plasma for igniting an arc is low (about 10 A), so that the waste of the forward end portion of the subelectrode is very small in the method according to the invention. Even if the forward end portion of the subelectrode 12 were wasted slightly, this poses no serious problem with regard to welding, because the ignition-plasma generating circuit aims at the generation of an ignition-plasma and is not required to contribute to the welding arc current, so that the circuit has essentially nothing to do with the welding electric circuit 8. Fig. 2b shows in a block diagram an ignition-plasma generating circuit 18 (25) using a high-frequency arc igniting process. The numeral 11 designates a plasma power source having a D.C. drooping characteristic. The plasma power source 11 has the subelectrode connected to its cathode through a high-frequency power source 14 and the nozzle member of the plasma projector 13 connected to its anode. The numeral 15 designates a high-frequency bypass capacitor. The plasma power source 11, the subelectrode 12, the nozzle member of the plasma projector 13, high-frequency power source 14 and high-frequency bypass capacitor 15 constitute the ignition-plasma generating circuit 18 (25). In the circuit 18 (25), a high-frequency voltage is impressed by the high-frequency power source 14 between the subelectrode 12 and the nozzle member of the plasma projector 13 to produce a spark discharge to cause dielectric breakdown to take place. Then, an electric current is passed from the plasma power source 11 to ignite an arc. The discharge gap between the nozzle member of the plasma projector 13 and subelectrode 12 can be as small as about 0.1 mm, so that the output voltage of the high frequency power source 14 only need to be about 1000 V. Thus, the high-frequency noise level is very low. Therefore, when the ignition-plasma generating circuit 18 shown in Fig. 2b is covered with a shield 16 and connected to an outside power source through a noise filter 17, the high-frequency noise can be readily and fully suppressed. It is not essential that the high-frequency power source 14 be connected to the cathode of the plasma power source 11. So long as the subelectrode 12, the nozzle member of the plasma projector 13, high-frequency power source 14 and high-frequency bypass capacitor 15 constitute a circuit, the high-frequency power source 14 may be located in any position as desired. In Fig. 2b, a high-frequency voltage produced by the high-frequency power source 14 is shown as being used for energizing the ignition-plasma generating circuit 18 (25), but any power source may be assembled in the ignition-plasma generating circuit 18 (25) so long as it is capable of producing a voltage of like level. It is possible to generate an ignition-plasma in actual practice by utilizing a capacitor discharge voltage produced by a capacitor power source or a surge voltage produced when the power supply is cut off. Fig. 2c shows in a block diagram an ignition-plasma generating circuit 18 (25) of the self-exothermic electrode arc igniting type. The numerals 85 and 84 designate a non-consumable electrode having two terminals (the non-consumable electrode having two terminals is used as an example and shall hereinafter be referred to as a filament) and a filament heating power source to cause the filament to generate heat. The filament heating power source 84 for heating the filament 85 may be either A.C. or D.C. and of any polarity. The filament heating power source 84 is connected to the terminals of the filament 85. One end of the filament 85 is connected to the cathode of the plasma power source 11 and the nozzle member of the plasma projector 13 is connected to the anode of the plasma power source 11. The filament heating power source 14 and filament 85 constitute a filament heating circuit 86, and the plasma power source 11, filament 85 and the nozzle member of the plasma projector 13 constitute the ignition-plasma generating circuit 18 (25). The plasma power source 11 is turned on and a no-load voltage is impressed between the filament 85 and the nozzle member of the plasma projector 13 to produce an electric field directed from the nozzle member of the plasma projector 13 toward the filament 85. Then, the filament heating power source 84 is turned on to pass a current to the filament 85 to cause the filament 84 to generate heat by the Joule effect. As the temperature of the filament 85 rises, the energy of the electrons in the filament 85 increases. When the sum of this energy and the energy of the electric field reaches a level sufficiently high to release the electrons, an arc is ignited between the filament 85 and the nozzle member of the plasma projector 13. (2) Operation Performed with a D.C. Straight Polarity Arc Using a Non-Consumable Electrode Fig. 1a shows an A.C. arc welding torch of the non-consumable electrode type. When it is desired to convert this welding torch into an arc welding torch of the D.C. nonconsumable electrode type in which the workpiece 3 has a positive polarity, one only has to eliminate the plasma projector 23 shown in Fig. 1a and mount the plasma projector 13 on a shield cap 6 so that the plasma ejection port is directed against the main electrode 2. One example of the use of the ignition-plasma generating circuit 18 shown in Fig. 2b as the ignition-plasma generating circuit 18 shown in Fig. 1c will be described. Attempts were made to ignite arcs continuously for 100 times by projecting ignition-plasma for 0.1 second each time under the following conditions: In the ignition-plasma generating circuit: No-load voltage impressed by plasma power source 11 ........ 100 V Ignition-plasma current ....... 10 A Flow rate of plasma gas ....... 3 ℓ/min Ar Ds = 1.0 mm, Lt = 1.0 mm, Lp = 2.0 mm and Ds = 1.0 mm In the welding electric circuit: No-load voltage impressed by welding power source 1 ....... 47 V Predetermined welding current ... 50 A Flow rate of shield gas ....... 20 ℓ/min Ar La = 2 mm, Lc = 5 mm, Lb = 10 mm and Dm = 2.4 mm The arc established each time was very stable, and no waste was observed in the main electrode 2, the subelectrode 12 and the nozzle member of the plasma projector 13. When a high-frequency voltage was produced, almost no change occurred in the voltage of the external power source. The measuring equipment and control unit used each had a microcomputer built therein. It was noted that no misoperation occurred in them due to a high-frequency noise. (3) Operation Performed with an A.C. Arc Using a Consumable Electrode (background to Figure 1d) Fig. 1b shows an A.C. arc welding torch of the consumable electrode type. In Fig. 1b, the A.C. welding power source 1 has two output terminals, one of the output terminals being connected to a welding wire (main discharging electrode) 2 of the welding torch 7 and the other output terminal being connected to the workpiece 3 to be welded. Thus, the welding power source 1, main discharging electrode 2 and workpiece 3 constitute a welding electric circuit 8. Located in the vicinity of the main electrode 2 is the plasma projector 13 for igniting an arc having a nozzle member connected to the anode of ignition-plasma device 10, and the subelectrode 12 is connected to the cathode of the ignition-plasma device 10. The ignition-plasma device 10, subelectrode 12 and the nozzle member of the plasma projector 13 constitute an ignition-plasma generating circuit 18. The nozzle member of the plasma projector 13 is connected to the workpiece. The numerals 26 and 28 designate an arc detector for detecting an arc established by the welding current and a welding wire feed control unit for driving feed rollers 29 respectively. The arc detector 26 detects that an arc is ignited and produces a signal for actuating the welding wire feed control unit 28 to commence the feeding of the welding wire 2. The use of a single electrode for igniting an arc has been described. However, the invention is not limited to the use of a single electrode for igniting an arc, and it may have application in an arc welding method using a plurality of electrodes. When the operation is started with a plurality of electrodes, there is no need to provide each electrode with a plasma projector, and only one plasma projector may be provided and used sequentially to ignite an arc. (4) Operation Performed with a D.C. Straight Polarity Using a Consumable Electrode Fig. 1b shows an A.C. arc welding torch using a consumable electrode. When it is desired to use this torch in a D.C. welding system in which the workpiece 3 is an anode, one only has to eliminate the plasma projector 23 shown in Fig. 1b and mount the plasma projector 13 on the shield cap 6. One example of the use of the ignition-plasma generating circuit 18 shown in Fig. 2b as the ignition-plasma generating circuit 18 shown in Fig. 1d will be described. Attempts were made to ignite arcs continuously for 100 times by projecting ignition-plasma for 0.1 second each time under the following conditions: In the ignition-plasma generating circuit: No-load voltage impressed by plasma power source 11 ..... 100 V Ignition-plasma current ..... 10 A Flow rate of plasma gas ..... 3 ℓ/min Ar Ds = 1.0 mm, Lt = 1.0 mm, Lp = 2.0 mm and ds = 1.0 mm In the welding electric circuit: Welding power source 1 impressed a no-load voltage of 47 V having a drooping characteristic of 0.07 V/A. Flow rate of shield gas ....... 20 ℓ/min Ar Wire feeding speed ............ 10 m/min Dm = 1.2 mm (solid wire) Le = 2 mm, La = 10 mm and Lb = 5 mm In each case, the arc established each time was very stable, and no sputter of large size was produced when arcs were ignited. The foregoing description refers to a plasma torch suitable for use in performing plasma welding. However, the invention is not limited to the use of plasma in welding, and the invention can have application in plasma cutting, plasma spraying (metallization), etc., since the principle of producing plasma in these operations is the same as in plasma welding. The system of the self-exothermic electrode arc igniting type shown in Fig. 2c may be used for performing welding, cutting, spraying (metallization), and heating, in addition to be used as the ignition-plasma generating circuit 18, 25 as described hereinabove. With regard to the manner in which the plasma projector 13 is mounted, the plasma projector 13 may be mounted on the shield cap 6 in such a manner that its plasma ejecting port 80 faces the main electrode 2 as shown in Fig. 3a. As shown in Fig. 3b, the plasma projector 13 may be insulated from the interior of the shield cap 6, and a dummy electrode 35 formed with a plasma feed port 36 communicating with the plasma ejecting port 80 of the plasma projector 13 may be attached to the inner surface of the shield cap 6. The dummy electrode 35 may be connected through a lead 37 to the workpiece 3 or the positive output terminal of the welding power source, so as to thereby electrically separate the plasma projector 13 from the workpiece 3. When the plasma projector 13 is arranged as described hereinabove, the welding electric circuit 8 is completely separated and insulated from the ignition-plasma generating circuit 18. Thus, by turning on the welding power source (D.C. output) 1, it is possible to form between the main electrode 2 and dummy electrode 35 an electric field which is directed from the latter toward the former. In this arrangement, the arc formed between the main electrode 2 and dummy electrode 35 is immediately transferred so that it is formed between the main electrode 2 and workpiece 3. A discharge from the main electrode 2 is not essentially applied to the plasma projector 13, so that the nozzle member of the latter is free from damage. In the plasma projector 13 shown in Fig. 4, the subelectrode 12 is in the form of a non-consumable electrode (filament 85) having at least two terminals each secured to one of two electrode holders 53 which are fittedin an insulating spacer 52 of substantially cylindrical configuration which is closed by an end cap 63 formed of insulating material. The insulating spacer 52 is formed with two holes extending through the electrode holders 53, and a threaded hole extending through its side wall to communicate with the internal space for threadably connecting a plasma gas pipe 62 to supply plasma gas therethrough. A nozzle member 51 is fitted to the insulating spacer 52 and connected through a lead to the positive output terminal of the plasma power source 11 of the ignition-plasma device 10 (Fig. 2c). The two electrode holders 53 are connected to the two terminals of the filament heating power source 84 of the ignition-plasma device 10 (Fig. 2c) by leads which extend through the holes formed in the insulating spacer 52. In the modification of the plasma projector 13 shown in Fig. 4, the holes necessary for passing a current to the filament 85 may be formed in the end cap 63 of insulating material, in place of being formed in the insulating spacer 52, so that leads can be extended therethrough to pass a current to the filament 85.

Claims: A method of igniting an arc without applying a high frequency voltage between an electrode (2) and a workpiece (3), the method comprising the steps of: arranging at least one electrode (2) and the electric tip of the electrode (2) so as to face the workpiece (3) on which an operation is to be performed, arranging an auxiliary electrode (13) so as to face the side surface of the electrode (2) or the side surface of the electrode tip, connecting the electrode (2) with its electrode tip to the negative terminal of a D.C. power source for performing the operation on the workpiece (3), the workpiece (3) being connected to the positive terminal of the D.C. power source, grounding both the auxiliary electrode (13) and the workpiece (3) so as to direct the electric field from the auxiliary electrode (13) towards the electrode (2) or the electrode tip, projecting an ignition-plasma into the electric field from the vicinity of the auxiliary electrode (13) against the electrode (2) or the electrode tip to form a cathode spot on the electrode (2) or the electrode tip, and first forming an arc between the electrode (2) or the electrode tip and the auxiliary electrode (13) and then transferring the cathode spot to the forward end of the electrode (2) by making use of the flow rate of shield gas and the shape of the electric field so that an arc is ignited to the electrode (2) and, defining the shape of the electric field by using a geometrical arrangement of the workpiece (3), electrode (2) and the auxiliary electrode (13) so that the arc formed between the electrode (2) and the auxiliary electrode (13) is transferred so that it is formed between the electrode (2) and the workpiece (3). A method as claimed in claim 1, wherein the ignition-plasma is generated by the self-heating of a non-consumable electrode (85) having two terminals for passing a heating current through the non-consumable electrode (85).

Inventors: NAKAMURA TAIZO, OTANI TADAYUKI, SAITO TOHRU, NAKAMURA, TAIZO, OTANI, TADAYUKI, SAITO, TOHRU, NAKAMURA, TAIZO C/O DAINIGIJUTSUKENKYUSHO, OTANI, TADAYUKI C/O DAINIGIJUTSUKENKYUSHO, SAITO, TOHRU C/O DAINIGIJUTSUKENKYUSHO
Applicants: NIPPON STEEL CORP, NIPPON STEEL CORPORATION
Application year: 1986
Main classification: B23K9
IPC codes: B23K9