Method for selection of weld control algorithms

• US 10,307,854 B2
• Filed: 01/11/2018
• Issued: 06/04/2019
• Est. Priority Date: 05/26/2011
• Status: Active Grant

• Current Assignee: Victor Equipment Co. (Enovis Corp.)
• Original Assignee: Victor Equipment Co. (Enovis Corp.)
• Inventors: Lambert, Roger H., Putnam, Geoffrey H.
• Primary Examiner(s): Laflame, Jr., Michael A
• Application Number:
  US15/868,005
• Publication Number:
  US 20180193940A1
• Time in Patent Office: 509 Days
• Field of Search: 2191305, 219132, 219136, 219137, 2191377, 219129, 219 75, 219108, 219110, 2191301, 21913021, 21913031, 21913033, 219137 PS, 219137 R, 700212
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/10 Other electric circuits therefor; Protective circuits; Remote controls

Abstract

A system and method for generating a weld are provided. The system receives a selection of a magnitude of a voltage. The system selects a first weld control algorithm when the magnitude of the voltage is in a first range of values. The system may also select a second weld control algorithm when the magnitude of the voltage is in a second range of values. The system may generate welding output power based on the first and second weld control algorithms.

Claims

1. A system for generating a weld for a welding machine, the system comprising:

a power circuit for generating welding output power for a welding process for the welding machine; and

a control circuit in communication with the power circuit and configured to;

receive a selected welding process from a plurality of welding processes, the plurality of welding processes including gas metal arc welding, flux core arc welding, shielded metal arc welding, and inert gas welding;

receive a value of a detected welding parameter for the welding machine;

automatically select a first weld control algorithm from a plurality of weld control algorithms in the case that the detected welding parameter is in a first range of values for the selected welding process, and generate and provide power to the welding machine based on the first algorithm; and

automatically select a second weld control algorithm from the plurality of weld control algorithms in the case that the detected welding parameter is in a second range of values for the selected welding process, and generate and provide power to the welding machine based on the second algorithm.

2. The system of claim 1, wherein the second range of values is between the first range of values.

3. The system of claim 1, wherein the welding process is flux core arc welding.

4. The system of claim 1, wherein the welding process is gas metal arc welding.

5. The system of claim 4, wherein the first weld control algorithm comprises a voltage control mode algorithm.

6. The system of claim 5, wherein the second weld control algorithm comprises a current control mode algorithm or a controlled dip transfer control, or the second weld control algorithm is implemented as a finite state machine.

7. The system of claim 4, wherein the first weld control algorithm comprises a proportional-integral loop.

8. The system of claim 7, wherein the second weld control algorithm comprises a finite state machine loop.

9. The system of claim 1, wherein the welding process is shielded metal arc welding.

10. The system of claim 9, wherein the first weld control algorithm comprises a current control mode algorithm.

11. The system of claim 10, wherein the second weld control algorithm comprises an arc force control mode algorithm.

12. The system of claim 1, wherein the control circuit is further configured to select a third weld control algorithm from the plurality of weld control algorithms when the detected welding parameter is in a third range of values.

13. The system of claim 1, wherein the first and second weld control algorithms are each selected from the group of a current control mode algorithm, a voltage control mode algorithm, a controlled dip transfer algorithm, a finite state machine and an arc force control mode algorithm.

14. A method for generating a weld for a welding machine, the method comprising:

receiving, at a control circuit, a detected welding parameter;

receiving a selected welding process from a plurality of welding processes, the plurality of welding processes including gas metal arc welding, flux core arc welding, shielded metal arc welding, and inert gas welding;

automatically selecting a first weld control algorithm from a plurality of weld control algorithms in the case that the detected welding parameter is in a first range of values for the selected welding process, and generate and provide power to the welding machine via the power circuit based on the first weld control algorithm;

automatically selecting a second weld control algorithm from the plurality of weld control algorithms in the case that the detected welding parameter is in a second range of values for the selected welding process, and generate and provide power to the welding machine via the power circuit based on the second weld control algorithm; and

generating and providing welding output power to the weld machine based on the selected first or second weld control algorithms.

15. The method of claim 14, wherein the first weld control algorithm comprises a current control mode algorithm.

16. The method of claim 14, wherein the second weld control algorithm comprises a voltage control mode algorithm.

17. The method of claim 14, wherein the second control algorithm comprises a controlled dip transfer control.

18. The method of claim 14, wherein the second control algorithm is implemented as a finite state machine.

19. The method of claim 14, wherein the second weld control algorithm comprises an arc force control mode algorithm.

20. A method for generating a weld for a welding machine, the method comprising:

receiving, at a control circuit, a value of a detected welding parameter;

receiving a selected welding process from a plurality of welding processes, the plurality of welding processes including gas metal arc welding, flux core arc welding, shielded metal arc welding, and inert gas welding;

automatically selecting a first weld control algorithm from a plurality of weld control algorithms in the case that the detected welding parameter is in a first range of values of the selected welding process, and generate and provide power to the welding machine via a power circuit based on the first weld control algorithm;

automatically selecting a second weld control algorithm from the plurality of weld control algorithms in the case that the detected welding parameter is in a second range of values of the selected welding process, and generate and provide power to the welding machine via the power circuit based on the second weld control algorithm;

generating and providing welding output power to the welding machine based on the selected first or second weld control algorithms;

continuously monitoring the value of the detected welding parameter after the welding output power has been provided to the welding machine; and

determining whether to change the selected first or second weld control algorithm based on the continuously monitored value of the detected welding parameter.