Method and apparatus for controlling weld states of a MIG welding process
First Claim
1. A method of regulating a power source having an 115V inverter to condition raw power into a form usable by a MIG welding apparatus, the method comprising the step of:
- determining a maximum allowable voltage error based on an output condition at a weld, wherein the maximum allowable voltage error comprises a clamped voltage error between a voltage feedback signal from the weld and a voltage command signal;
determining an instantaneous command current based at least in part on the maximum allowable voltage error and based at least in part on inputs relating to operation of the MIG welding apparatus, wherein the inputs are different than the voltage command signal; and
inputting a signal proportional to the instantaneous command current to a controller of the 115V inverter, the signal designed to regulate the controller to provide a control signal to regulate an output of the 115V inverter.
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Abstract
Methods, controllers, and power sources for controlling weld states of a MIG welding machine having a 115 volt inverter are provided. The regulation of a power source may include determining a command current signal based on a maximum allowable voltage error determined from the output condition at the weld. The signal may be provided to a controller that regulates the output of the 115 volt inverter. A MIG welding power source may include the 115 volt inverter and a processor that determines a maximum allowable voltage offset from a voltage feedback signal and a voltage level. The processor may provide a signal based on a determined instantaneous command current to regulate the 115 volt inverter.
41 Citations
20 Claims
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1. A method of regulating a power source having an 115V inverter to condition raw power into a form usable by a MIG welding apparatus, the method comprising the step of:
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determining a maximum allowable voltage error based on an output condition at a weld, wherein the maximum allowable voltage error comprises a clamped voltage error between a voltage feedback signal from the weld and a voltage command signal; determining an instantaneous command current based at least in part on the maximum allowable voltage error and based at least in part on inputs relating to operation of the MIG welding apparatus, wherein the inputs are different than the voltage command signal; and inputting a signal proportional to the instantaneous command current to a controller of the 115V inverter, the signal designed to regulate the controller to provide a control signal to regulate an output of the 115V inverter. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A controller to regulate a MIG welding power source having an 115V inverter, the controller configured to execute a series of instructions that when executed cause the controller to:
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determine a maximum allowable voltage variance based on a monitored condition at a weld that receives power thereat from the MIG welding power source, wherein the monitored condition comprises the condition of the welding arc load and the maximum allowable voltage variance comprises the variance between a voltage feedback signal and a voltage command signal; determine an instantaneous command current based at least in part on the maximum allowable voltage variance and based at least in part on inputs relating to operation of the MIG welding power source, wherein the inputs are different than the voltage command signal; and provide an input to the 115V inverter that is a function of the instantaneous command current to cause the MIG welding power source to provide a desired output. - View Dependent Claims (12, 13, 14, 15)
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16. A MIG welding power source comprising:
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a 115V inverter; and a processor programmed to; receive a voltage feedback signal from a weld; determine a voltage offset from the voltage feedback signal and a commanded voltage level; clamp the voltage offset at a maximum level based on an output condition at the weld; determine an instantaneous command current based at least in part on the voltage offset and based at least in part on inputs relating to operation of the MIG welding power source, wherein the inputs are different that the commanded voltage level; input a signal to the 115V inverter proportioned to the instantaneous command current to cause the 115V inverter to output a desired output. - View Dependent Claims (17, 18, 19, 20)
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Specification