Method and system of welding with a power supply having a single welding mode

Patent metadata

Field	Value
Publication number	US-9623505-B2
Application number	US-201313798219-A
Country	US
Kind code	B2
Filing date	Mar 13, 2013
Priority date	Mar 13, 2013
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

A welding power supply and method are provided with a single welding mode in its controller such that the power supply can change from full DCEN output to AC output to a full DCEP output without having to change welding modes.

First claim

The invention claimed is:

1. A welding power supply, comprising:
a welding output circuit configured to output a plurality of different welding waveforms, where at least some of said plurality of different welding waveforms include a DC electrode negative welding waveform, an AC welding waveform and a DC electrode positive welding waveform; and
a welding controller coupled to said welding output circuit, said welding controller configured to execute a welding mode to output a welding waveform from said plurality of different welding waveforms;
wherein said welding mode includes a starting logic, a steady state logic, an ending logic, and a plurality of data points that define said welding waveform, and
wherein said welding controller is configured such that, during welding in response to a request to change said welding waveform, said controller changes from said welding waveform to another welding waveform of said plurality of different welding waveforms by changing at least some of said plurality of data points, without said controller changing to a different welding mode and without initiating anyone of the starting or ending logic present in said controller.

2. The welding power supply of claim 1 , wherein said controller controls said welding output circuit based on a threshold parameter, where when said threshold parameter is exceeded said controller automatically changes said welding waveform to said another welding waveform.

3. The welding power supply of claim 2 , wherein said threshold parameter is a peak current duration threshold parameter.

4. The welding power supply of claim 2 , wherein said threshold parameter is a peak current duration threshold parameter in a range of 0.8 to 2 ms, and
wherein when a peak current duration of said welding waveform is adjusted to be between 0.8 to 2 ms, said controller changes said output of said welding output circuit from said welding waveform to said another welding waveform.

5. The welding power supply of claim 2 , wherein said threshold parameter is a peak current duration threshold parameter that is 1 ms, and
wherein, when a peak current duration of said welding waveform is adjusted to be below 1 ms, said controller changes said output of said welding output circuit from said welding waveform to said another welding waveform.

6. The welding power supply of claim 1 , wherein, during welding in response to said request to change said welding waveform, at least some of said plurality of data points are changed by said controller to change said welding waveform from anyone of said DC electrode negative welding waveform, said AC welding waveform and said DC electrode positive welding waveform, to any other one of said DC electrode negative welding waveform, said AC welding waveform and said DC electrode positive welding waveform without said controller changing to a different welding mode and without initiating anyone of the starting or ending logic present in said controller.

7. The welding power supply of claim 1 , wherein said controller changes at least some of said plurality of data points based on a user input during said welding.

8. The welding power supply of claim 1 , wherein at least some of said plurality of data points control at least one of a duration of a peak current, a frequency, a peak current level, a background current level, and a current ramp rate of said welding waveform.

9. The welding power supply of claim 1 , wherein at least some of said plurality of data points control a duration of a peak current and, during welding in response to said request to change said welding waveform, the controller adjusts the duration of any peak current to 0ms without changing from said welding mode.

10. The welding power supply of claim 1 , wherein at least some of said plurality of data points control a duration of a peak current and, during welding in response to said request to change said welding waveform, the controller adjusts the duration of any peak current to change said welding waveform from anyone of said DC electrode negative welding waveform, said AC welding waveform and said DC electrode positive welding waveform, to any other one of said DC electrode negative welding waveform, said AC welding waveform and said DC electrode positive welding waveform without said controller changing to a different welding mode and without initiating anyone of the starting or ending logic present in said controller.

11. A method of welding, comprising:
outputting a welding waveform from a welding output circuit which is capable of outputting a plurality of different welding waveforms, where at least some of said plurality of different welding waveforms are a DC electrode negative welding waveform, an AC welding waveform and a DC electrode positive welding waveform; and
executing a welding mode to control said welding output circuit to output a welding waveform from said plurality of different welding waveforms;
wherein said welding mode includes a starting logic, a steady state logic, and ending logic, and a plurality of data points that define said welding waveform, and
wherein said executing a welding mode to control said welding output circuit includes, during welding in response to a request to change said welding waveform, changing said welding waveform to another welding waveform of said plurality of different welding signals by changing at least some of said plurality of data points, without changing to a different welding mode and without initiating anyone of the starting or ending logic.

12. The welding method of claim 11 , further comprising automatically changing said welding waveform to said another welding waveform when a threshold parameter is exceeded.

13. The welding method of claim 12 , wherein said threshold parameter is a peak current duration threshold parameter.

14. The welding method of claim 12 , wherein said threshold parameter is a peak current duration threshold parameter in a range of 0.8 to 2 ms, and
the method further comprises changing from said welding waveform to said another waveform when a peak current duration of said welding waveform is adjusted to be between 0.8 to 2 ms.

15. The welding method of claim 12 , wherein said threshold parameter is a peak current duration threshold parameter that is 1 ms, and
wherein the method further comprises changing from said welding waveform to said another waveform when a peak current duration of said welding signal is adjusted to be below 1 ms.

16. The welding method of claim 11 , wherein, during welding in response to said request to change said welding waveform, at least some of said plurality of data points are changed to change said welding waveform from anyone of said DC electrode negative welding waveform, said AC welding waveform and said DC electrode positive welding waveform, to any other one of said DC electrode negative welding waveform, said AC welding waveform and said DC electrode positive welding waveform without chancing to a different welding mode and without initiating anyone of the starting or ending logic.

17. The welding method of claim 11 , wherein said changing at least some of said plurality of data points is based on a user input during said welding.

18. The welding method of claim 11 , wherein at least some of said plurality of data points control at least one of a duration of a peak current, a frequency, a peak current level, a background current level, and a current ramp rate of said welding waveform.

19. The welding method of claim 11 , wherein at least some of said plurality of data p

Assignees

• Lincoln Global Inc

Inventors

• Daniel Joseph A
• Peters Steven R

Classifications

• B23K9/1006

  Power supply · CPC title

• B23K9/1043

  characterised by the electric circuit (B23K9/1012 takes precedence) · CPC title

• B23K9/1012

  characterised by parts of the process · CPC title

• B23K9/09

  Arrangements or circuits for arc welding with pulsed current or voltage · CPC title

• B23K9/1062

  with computing means · CPC title