SYSTEMS AND METHODS TO CONTROL GAS TUNGSTEN ARC WELDING AND PLASMA ARC WELDING
First Claim
Patent Images
1. A method for controlling a welding process comprising:
- applying a base current to a welding torch for a first time period;
applying an increasing current that increases from the base current to a peak current, to the welding torch for a second time period following the first time period;
maintaining applying of the peak current for a third time period following the second time period;
periodically sampling an arc voltage of the welding process to generate a series of arc voltage values;
determining a depth of a weld pool on a work piece surface based on one or more of the arc voltage values; and
stopping the applying of the peak current when the depth of the weld pool exceeds a predetermined threshold.
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Abstract
A control system for a welding process controls the current applied to the welding torch in either a manual or automatic welding system. The arc voltage is monitored to determine when full penetration of the weld pool has occurred so that the current to the welding torch can be stopped. The arc voltage or the slope of the increase of the arc voltage can be used to operate the control algorithm. Additional variables such as torch speed, torch angle, and weld position can be used to influence the control algorithm. The contemplated systems include both GTAW and PAW welding process as well as others.
17 Citations
36 Claims
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1. A method for controlling a welding process comprising:
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applying a base current to a welding torch for a first time period; applying an increasing current that increases from the base current to a peak current, to the welding torch for a second time period following the first time period; maintaining applying of the peak current for a third time period following the second time period; periodically sampling an arc voltage of the welding process to generate a series of arc voltage values; determining a depth of a weld pool on a work piece surface based on one or more of the arc voltage values; and stopping the applying of the peak current when the depth of the weld pool exceeds a predetermined threshold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method for controlling a welding process comprising:
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applying a base current to a welding torch for a first time period; applying a peak current, greater than the base current, to the welding torch for a second time period following the first time period; periodically sampling an arc voltage of the welding process to generate a series of arc voltage slope values; determining a penetration depth of the welding process on a work piece surface based on one or more of the arc voltage slope values; and stopping the applying of the peak current when the penetration depth exceeds a predetermined threshold. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A method of compensating for a skill of a manual welder, comprising:
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monitoring weld penetration during a manual welding operation of a welding torch; and based on the monitored weld penetration, adjusting the parameters of the welding torch. - View Dependent Claims (32, 33)
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34. A method for controlling a welding process using a welding torch, comprising:
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determining a reference arc voltage representing a top surface of a weld pool; applying a peak current to the torch to perform the welding process; detecting a sampled arc voltage during the welding process; and stopping the applying of the peak current, if a difference between the reference arc voltage and the sampled arc voltage exceeds a predetermined threshold.
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35. The method of claim 34, wherein the difference indicates a weld penetration amount.
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35-37. -37. (canceled)
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36. The method of claim 34, wherein determining the reference arc voltage includes:
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applying a base current for a first time period; increasing the base current to a predetermined current value; and determining the reference arc voltage when the predetermined current value is reached.
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Specification