Arc welding adjustable short circuit threshold

Patent metadata

Field	Value
Publication number	US-12337425-B2
Application number	US-202117465319-A
Country	US
Kind code	B2
Filing date	Sep 2, 2021
Priority date	Sep 2, 2021
Publication date	Jun 24, 2025
Grant date	Jun 24, 2025

Abstract

A shielded metal arc welding system includes a stick electrode holder, a stick electrode clamped by the holder, and a welding power supply operatively connected to the holder and configured to supply a welding current to the electrode through the holder. The power supply includes a memory storing both of a short circuit threshold voltage level and an arcing threshold voltage level. A welding voltage level is detected during an initial shorting of the electrode to a workpiece for commencing a welding operation. Both of the short circuit threshold voltage level and the arcing threshold voltage level are adjusted based on the detected welding voltage level. A short circuit clearing routine is activated when the welding voltage level is equal to or less than the adjusted short circuit threshold voltage level, and deactivated when the welding voltage level is equal to or greater than the adjusted arcing threshold voltage level.

First claim

What is claimed is:

1. An arc welding method, comprising the steps of:
providing a shielded metal arc welding system, including:
a stick electrode holder;
a stick electrode clamped by the stick electrode holder; and
a welding power supply operatively connected to the stick electrode holder and configured to supply a welding current to the stick electrode through the stick electrode holder, wherein the welding power supply includes a memory storing both of a short circuit threshold voltage level and an arcing threshold voltage level;

detecting, by the welding power supply, a welding voltage level during an initial shorting of the stick electrode to a workpiece for commencing an arc welding operation;
comparing the welding voltage level detected during the initial shorting of the stick electrode to the workpiece to the short circuit threshold voltage level or to an expected short circuit voltage level;
adjusting, by the welding power supply, both of the short circuit threshold voltage level and the arcing threshold voltage level upward based on the detected welding voltage level being greater than at least one of the short circuit threshold voltage level and the expected short circuit voltage level;
activating, by the welding power supply, a short circuit clearing routine during the arc welding operation when the welding voltage level is equal to or less than the adjusted short circuit threshold voltage level; and
deactivating, by the welding power supply, the short circuit clearing routine when the welding voltage level is equal to or greater than the adjusted arcing threshold voltage level.

2. The arc welding method of claim 1 , further comprising the step of calculating a resistance level of a welding circuit from the welding voltage level.

3. The arc welding method of claim 2 , further comprising the step of calculating an inductance level of the welding circuit from the welding voltage level.

4. The arc welding method of claim 1 , further comprising the step of readjusting, by the welding power supply, both of the short circuit threshold voltage level and the arcing threshold voltage level, based on both of the welding voltage level detected during the initial shorting of the stick electrode to the workpiece and a subsequent welding voltage level detected during a subsequent shorting of the stick electrode to the workpiece during the arc welding operation.

5. An arc welding system, comprising:
a stick electrode holder comprising a clamp for holding a stick electrode; and
a welding power supply operatively connected to the stick electrode holder via a cable, wherein the welding power supply is configured to supply a welding current to the stick electrode through the stick electrode holder and cable,
wherein the welding power supply includes:
a memory storing both of a short circuit threshold voltage level and an arcing threshold voltage level;
a controller operatively connected to the memory, and
a voltage sensor, operatively connected to the controller, that measures a welding voltage level during an arc welding operation,
wherein the welding power supply is configured to:
detect the welding voltage level during an initial shorting of the stick electrode to a workpiece for commencing the arc welding operation;
compare the welding voltage level detected during the initial shorting of the stick electrode to the workpiece to the short circuit threshold voltage level or to an expected short circuit voltage level;
automatically upwardly adjust both of the short circuit threshold voltage level and the arcing threshold voltage level based on the welding voltage level detected during the initial shorting of the stick electrode to the workpiece being greater than at least one of the short circuit threshold voltage level and the expected short circuit voltage level;
activate a short circuit clearing routine during the arc welding operation when the welding voltage level is equal to or less than the adjusted short circuit threshold voltage level; and
deactivate the short circuit clearing routine when the welding voltage level is equal to or greater than the adjusted arcing threshold voltage level.

6. The arc welding system of claim 5 , wherein the welding power supply is configured calculate a resistance level of a welding circuit from the welding voltage level.

7. The arc welding system of claim 6 , wherein the welding power supply is configured to calculate an inductance level of the welding circuit from the welding voltage level.

8. The arc welding system of claim 5 , wherein the welding power supply is configured to automatically readjust both of the short circuit threshold voltage level and the arcing threshold voltage level based on both of the welding voltage level detected during the initial shorting of the stick electrode to the workpiece and a subsequent welding voltage level detected during a subsequent shorting of the stick electrode to the workpiece during the arc welding operation.

9. An arc welding system, comprising: a welding torch; a consumable electrode extending from the welding torch; and a welding power supply operatively connected to the welding torch via a cable, wherein the welding power supply is configured to supply a welding current to the consumable electrode through the welding torch and cable, wherein the welding power supply includes: a memory storing a short circuit threshold voltage level or a short circuit threshold resistance level: a controller operatively connected to the memory, and a voltage sensor, operatively connected to the controller, that measures a welding voltage level during an arc welding operation, wherein the welding power supply is configured to: detect the welding voltage level during a shorting of the consumable electrode to a workpiece; automatically adjust the short circuit threshold voltage level or the short circuit threshold resistance level based on the welding voltage level detected during the shorting of the consumable electrode to the workpiece, wherein the welding power supply is configured to automatically increase the short circuit threshold voltage level or the short circuit threshold resistance level when the welding voltage level or a welding circuit resistance level detected during the shorting of the consumable electrode to the workpiece is higher than an expected level; and activate a short circuit clearing routine during the arc welding operation when the welding voltage level is equal to or less than the adjusted short circuit threshold voltage level or when the welding circuit resistance level is equal to or less than the adjusted short circuit threshold resistance level.

10. The arc welding system of claim 9 , wherein the welding torch includes a clamp for holding the consumable electrode.

11. The arc welding system of claim 9 , wherein the welding power supply is configured to calculate the welding circuit resistance level from the welding voltage level.

12. The arc welding system of claim 11 , wherein the welding power supply is configured to calculate an inductance level of a welding circuit from the welding voltage level.

13. The arc welding system of claim 9 , wherein the welding power supply is configured to automatically readjust the short circuit threshold voltage level or the short circuit threshold resistance level based on both of the welding voltage level detected during the shorting of the consumable electrode to the workpiece and a subsequent welding voltage level detected during a subsequent shorting of the consumable electrode to the workpiece during the arc welding operation.

Assignees

• Lincoln Global Inc

Inventors

• Henry Judah B
• Peters Steven R

Classifications

• B23K9/073

  Stabilising the arc · CPC title

• B23K9/0956

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

• B23K9/14

  making use of insulated electrodes · CPC title

• B23K9/0953 Primary

  using computing means · CPC title