Methods and apparatus to control a weld current amperage

Patent metadata

Field	Value
Publication number	US-10427237-B2
Application number	US-201615040632-A
Country	US
Kind code	B2
Filing date	Feb 10, 2016
Priority date	Feb 10, 2016
Publication date	Oct 1, 2019
Grant date	Oct 1, 2019

Abstract

Methods and apparatus to control a weld current amperage are disclosed. A disclosed example method includes identifying an amperage parameter of a welding device, determining a voltage set point based on the amperage parameter and a voltage correction factor, outputting weld current based on the amperage parameter and the voltage set point, comparing a measured voltage corresponding to the weld current to a threshold, and when the measured voltage satisfies the threshold, and adjusting an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage using a first amperage-voltage relationship.

First claim

What is claimed is:

1. A method to provide a controlled current to an electrode, comprising:
identifying, by circuitry, an amperage parameter of a welding device;
determining, by a voltage set point calculator, a voltage set point based on the amperage parameter and a voltage correction factor;
outputting, by a power converter, weld current based on the amperage parameter and the voltage set point;
comparing, by an arc voltage monitor, a measured voltage corresponding to the weld current to a threshold; and
adjusting, based on the comparison, by an amperage adjuster an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage.

2. The method as defined in claim 1 , wherein:
when the measured voltage satisfies the threshold, adjusting an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage using a sloping amperage-voltage relationship; and
when the measured voltage does not satisfy the threshold, adjusting the amperage of the weld current based on the amperage parameter, the voltage set point, and a second amperage-voltage relationship.

3. The method as defined in claim 1 , wherein the threshold is a higher voltage than the voltage set point.

4. The method as defined in claim 1 , wherein the adjusting of the amperage of the weld current comprises causing the amperage to be greater than or equal to the amperage parameter while the weld current is present.

5. The method as defined in claim 1 , wherein identifying the amperage parameter comprises receiving the amperage parameter from at least one of a user interface or a communications interface.

6. The method as defined in claim 1 , wherein the voltage correction factor comprises an amperage-voltage curve.

7. The method as defined in claim 1 , wherein the voltage correction factor has a negative slope.

8. A welding device to provide a controlled current to an electrode, comprising:
an interface configured to receive an amperage parameter;
a voltage set point calculator configured to set a voltage set point based on the amperage parameter and a voltage correction factor;
a power converter configured to output weld current based on the amperage parameter and the voltage set point;
an arc voltage monitor configured to compare a measured voltage corresponding to weld current to a threshold; and
an amperage adjuster configured to adjust, based on the comparison, an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage.

9. The welding device as defined in claim 8 , wherein the amperage adjuster is configured to:
when the measured voltage satisfies the threshold, adjust an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage using a sloping amperage-voltage relationship; and
when the measured voltage does not satisfy the threshold, adjust the amperage of the weld current based on the amperage parameter, the voltage set point, and a second amperage-voltage relationship.

10. The welding device as defined in claim 9 , wherein the amperage adjuster is configured to access a first portion of an amperage-voltage curve to use the sloping amperage-voltage relationship and access a second portion of the amperage-voltage curve to use the second amperage-voltage relationship.

11. The welding device as defined in claim 8 , wherein the amperage adjuster is configured to control the amperage of the weld current to be equal to or greater than the amperage parameter.

12. The welding device as defined in claim 8 , wherein the voltage set point calculator is configured to set the voltage set point to a voltage equal to or less than the threshold.

13. The welding device as defined in claim 8 , wherein the interface comprises a user interface configured to receive a user selection of the amperage parameter.

14. The welding device as defined in claim 8 , wherein the interface comprises a communications interface configured to receive a selection of the amperage parameter from another device.

15. The welding device as defined in claim 8 , wherein the voltage set point calculator is configured to set the voltage set point using an amperage-voltage curve of the voltage correction factor.

16. The welding device as defined in claim 8 , wherein the voltage set point calculator is configured to set the voltage set point using an amperage-voltage curve of the voltage correction factor, wherein the voltage correction factor has a negative slope.

17. A non-transitory machine readable medium comprising machine readable instructions which, when executed, cause a welding device to:
identify, via circuitry, an amperage parameter of the welding device;
determine, by a voltage set point calculator, a voltage set point based on the amperage parameter and a voltage correction factor;
output, by a power conversion circuit, weld current based on the amperage parameter and the voltage set point;
compare, by an arc voltage monitor, a measured voltage corresponding to the weld current to a threshold; and
adjust, based on the comparison, by an amperage adjuster an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage.

18. The machine readable medium as defined in claim 17 , wherein the instructions are further to cause the amperage adjuster to:
when the measured voltage satisfies the threshold, adjust an amperage of the weld current based on the amperage parameter, the voltage set point, and the measured voltage using a sloping amperage-voltage relationship; and
when the measured voltage does not satisfy the threshold, adjust, based on the amperage parameter, the voltage set point, and a second amperage-voltage relationship, the amperage of the weld current.

19. The machine readable medium as defined in claim 17 , wherein the instructions are to cause the amperage adjuster to adjust of the amperage of the weld current by causing the amperage to be greater than or equal to the amperage parameter while the weld current is present.

20. The machine readable medium as defined in claim 17 , wherein the instructions are to cause the voltage set point calculator to calculate the voltage set point to a voltage equal to or less than the threshold.

21. The machine readable medium as defined in claim 17 , wherein the instructions are to cause the circuitry to identify the amperage parameter by accessing the amperage parameter received from at least one of a user interface or a communications interface.

22. The machine readable medium as defined in claim 17 , wherein the instructions are further to cause the circuitry to determine that a gouging operation is selected, the voltage correction factor being based on selection of the gouging operation.

Assignees

• Illinois Tool Works

Inventors

• Ulrich James F
• Casner Bruce A
• Stapp Zakary

Classifications

• B23K9/0953 Primary

  using computing means · CPC title

• B23K9/0956

  using sensing means, e.g. optical · CPC title

• B23K9/013

  Arc cutting, gouging, scarfing or desurfacing · CPC title