Method to improve process stabilization

• US 9,943,923 B2
• Filed: 05/25/2012
• Issued: 04/17/2018
• 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:
  US13/480,656
• Publication Number:
  US 20120298641A1
• Time in Patent Office: 2,153 Days
• Field of Search: 21912403, 21913021, 2191305, 21913051, 219136, 21913771, 219137 PS, 21912113
• CPC Class Codes: B23K 9/0673 Ionisation of the arc gap by means of a tension with a step front (pulses or high frequency tensions)
• CPC Class Codes: B23K 9/073 Stabilising the arc
• CPC Class Codes: B23K 9/09 Arrangements or circuits for arc welding with pulsed current or voltage
• CPC Class Codes: B23K 9/10 Other electric circuits therefor; Protective circuits; Remote controls

Abstract

Systems and methods for providing an improved start in a welding are provided. The system may include a power circuit and a control circuit: The power circuit may generate welding output power for a welding process. The control circuit may control the start of the welding process, for example, by generating a current pulse.

Claims

1. A system for providing an improved start in a welding process, the system comprising:

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

a control circuit in communication with the power circuit to control the start of the welding process, the control circuit being configured to;

receive a selection of a run in setting and a selection of a voltage;

determine a start current pulse and a run time current pulse, wherein the start current pulse and run time current pulse each have peak magnitudes that are determined based on the run in setting and the selection of the voltage, wherein the peak magnitude of the start current pulse is determined according to the formula A+B*(the run in setting)+C*(the selection of the voltage), wherein A, B, and C are each amperage values;

provide the start current pulse at a start of the welding process for a pre-determined period of time determined by the run-in setting and the selection of the voltage; and

provide the run time current pulse after the pre-determined period of time has expired, wherein the run time current pulse is greater than the start current pulse.

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

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

4. The system of claim 1 wherein the peak magnitude is substantially a linear function of the run in setting.

5. The system of claim 1 wherein the start current pulse is provided for a predefined period of time determined according the formula A′

+B′

*(the run in setting)+C′

*(the voltage setting), wherein A′

, B′

, and C′

are each time values.

6. The system of claim 5 wherein the predefined period of time is independent of user-selected welding parameters.

7. The system of claim 1 wherein the start current pulse has the peak magnitude at the start of the pre-determined period of time and decreases substantially linearly as a function of time to a magnitude of substantially zero at the end of the pre-determined period of time.

8. The system of claim 1 wherein the start current pulse has the peak magnitude at the start of the period of time and decreases substantially exponentially as a function of time to a magnitude of substantially zero at the end of the pre-determined period of time.

9. A system for providing an improved start in a welding process, the system comprising:

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

a control circuit in communication with the power circuit to control the start of the welding process, the control circuit being configured to;

receive a selection of a voltage setting;

receive a selection of a run-in percentage;

determine a start current pulse and a run time current pulse, wherein the start current pulse and run time current pulse each have peak magnitudes that are determined based on the voltage setting and the run-in percentage, wherein the peak magnitude of the start current pulse is determined according to the formula A+B*(run-in percentage)+C*(the voltage setting), wherein A, B, and C are each amperage values;

provide a start current pulse at a start of the welding process for a pre-determined period of time determined by the run-in percentage and the voltage setting; and

provide the run time current pulse after the period of time has expired, wherein the run time current pulse is greater than the start current pulse.

10. The system of claim 9 wherein the welding process is gas metal arc welding.

11. The system of claim 9 wherein the welding process is flux core arc welding.

12. The system of claim 9 wherein the peak magnitude is substantially a linear function of the voltage setting.

13. The system of claim 9 wherein the predefined period of time is independent of user-selected welding parameters.

14. The system of claim 9 wherein the start current pulse has the peak magnitude at the start of the period of time and decreases substantially linearly as a function of time to a magnitude of substantially zero at the end of the period of time.

15. The system of claim 9 wherein the start current pulse has the peak magnitude at the start of the period of time and decreases substantially exponentially as a function of time to a magnitude of substantially zero at the end of the period of time.

16. A system for providing an improved start in a welding process, the system comprising:

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

a control circuit in communication with the power circuit to control the start of the welding process, the control circuit being configured to;

receive a selection of a run in percentage;

receive a selection of a voltage;

determine a start current pulse and a run time current pulse, wherein the start current pulse and run time current pulse each have peak magnitudes that are determined based on the run in percentage and the selection of the voltage, wherein the peak magnitude of the start current pulse is determined according to the formula A+B*(run in setting)+C*(the selection of the voltage), wherein A, B, and C are each amperage values;

provide the start current pulse at a start of the welding process for a predefined period of time that is determined by the run in percentage and the selection of the voltage; and

provide the run time current pulse after the predefined period of time has expired, wherein the run time current pulse is greater than the start current pulse.

17. The system of claim 16 wherein the welding process is gas metal arc welding.

18. The system of claim 16 wherein the welding process is flux core arc welding.

19. The system of claim 16 wherein the predefined period of time is substantially a linear function of the run in percentage.

20. The system of claim 16, determined according to the formula A′

+B′

*(the run in setting)+C′

*(the selection of the voltage), wherein A′

, B′

, and C′

are each time values.

21. The system of claim 20 wherein the predefined period of time is substantially a linear function of the voltage setting.

22. The system of claim 16 wherein a magnitude of the start current pulse is independent of user-selected welding parameters.

23. The system of claim 16 wherein the start current pulse has a maximum magnitude at the start of the predefined period of time and decreases substantially linearly as a function of time to a magnitude of about zero at the end of the predefined period of time.

24. The system of claim 23 wherein the maximum magnitude is between substantially 250 and substantially 1000 amps.

25. The system of claim 16 wherein the start current pulse has the peak magnitude at the start of the period of time and decreases substantially exponentially as a function of time to a magnitude of substantially zero at the end of the period of time.