Abstract:
Systems and methods for optimally setting a coarse adjustment knob and a fine adjustment knob (i.e. a rheostat) on a user interface of a stick welding system via an intuitive display are provided. Certain embodiments of the present disclosure relate to achieving the correct amperage setting for a given electrode through icons that allow easy association between an electrode and the proper coarse and fine adjustment knob settings. In one embodiment, the user interface includes a color coded bar chart that may be used to identify the proper coarse and fine adjustment knob settings for a given electrode. In another embodiment, the user interface includes panels above the coarse adjustment knob that contain icons with arrows that indicate an appropriate range of rheostat settings for a given electrode. Additionally, methods that may be used to set the coarse and fine adjustment knobs on the disclosed exemplary interfaces are provided.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a U.S. Non-provisional patent application of U.S. Provisional Patent Application No. 61/080,843, entitled “Color Coded Bar Chart User Interface for Welder”, filed Jul. 15, 2008, which is herein incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates generally to user interfaces of welding systems, and more particularly to systems and methods for optimally setting a coarse adjustment knob and a fine adjustment knob (i.e. a rheostat) on a user interface of a stick welding system via an intuitive display. 
         [0003]    Stick welding is a process that has increasingly become ubiquitous in all industries. While such processes may be automated in certain contexts, a large number of applications continue to exist for manual welding operations, the success of which relies heavily on the welder choosing the proper amperage setting for the chosen stick electrode. For instance, an improper amperage setting can lead to sagging welds, arc loss and overall poor weldments. However, even experienced welders often have difficulty achieving the proper amperage setting during welding since both the coarse adjustment knob and the fine adjustment knob must be properly set for a given electrode to operate at the correct amperage setting. Furthermore, amperage displays typically do not exist on stick welding system interfaces, making it difficult for the user to know what the amperage setting is and whether it is within the range recommended by the manufacturer. 
         [0004]    Traditionally, welders rely on experience and the look of the weld to approximate the proper amperage setting for a given electrode. It is now recognized that such traditional methods may lead to welders operating outside of the amperage setting range recommended by the manufacturer for a given electrode. Additionally, it is now recognized that traditional methods present difficulties for inexperienced welders who may waste time and wear down materials trying to find the proper amperage setting for the chosen electrode. 
       BRIEF DESCRIPTION 
       [0005]    The present disclosure is directed to systems and methods relating to user interfaces of welding systems. Certain embodiments of the present disclosure relate to achieving the correct amperage setting for a given electrode through icons that allow easy association between an electrode and the proper coarse and fine adjustment knob settings. In particular, the present disclosure relates to systems and methods for optimally setting a coarse adjustment knob and a fine adjustment knob (e.g. a rheostat) on a user interface of a stick welding system via an intuitive display. In one embodiment, the user interface includes a visually coded (e.g., color coded or pattern coded) bar chart that may be used to identify the proper coarse and fine adjustment knob settings for a given electrode. In another embodiment, the user interface includes panels above the coarse adjustment knob that contain icons with arrows that indicate an appropriate range of rheostat settings for a given electrode. Additionally, methods that may be used to set the coarse and fine adjustment knobs on the disclosed exemplary interfaces are provided. 
     
    
     
       DRAWINGS 
         [0006]    These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
           [0007]      FIG. 1  is a perspective view of an exemplary stick welding power supply unit in accordance with aspects of the present disclosure; 
           [0008]      FIG. 2  illustrates an exemplary control panel including a visually coded bar chart, a coarse adjustment knob, and a rheostat in accordance with aspects of the present disclosure; 
           [0009]      FIG. 3  illustrates an exemplary method of operating the exemplary control panel of  FIG. 2  to optimally set an amperage setting for a chosen electrode in accordance with aspects of the present disclosure; 
           [0010]      FIG. 4  illustrates an exemplary control panel including a low setting panel and a high setting panel above a coarse adjustment knob and a rheostat in accordance with aspects of the present disclosure; and 
           [0011]      FIG. 5  illustrates an exemplary method of operating the exemplary control panel of  FIG. 4  to optimally set an amperage setting for a chosen electrode in accordance with aspects of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    It is now recognized that experience and the look of a weld may form an insufficient basis for a user to correctly determine the proper amperage setting for a given stick electrode. Additionally, it is now recognized that users often expend valuable time and effort trying to achieve the amperage setting recommended by the manufacturer for the chosen electrode. Accordingly, the present disclosure facilitates fast and easy setup of the correct amperage setting by visually and intuitively communicating knob settings that achieve the desired amperage setting for commonly used stick electrodes. The present disclosure may reduce the amount of time sales personnel, rental agents, and trainers spend teaching others how to properly use the system due to its convenience and simplicity. 
         [0013]      FIG. 1  illustrates an exemplary stick welding power supply  10 , which functions to power, control, and provide consumables to a welding operation in accordance with aspects of the present disclosure. The front side of the power supply unit  10  in the illustrated embodiment contains a control panel  12 , through which a user may control the supply of materials, such as power, gas flow, and so forth for a welding operation. In some embodiments, ports on the control panel  12  may allow the user to connect equipment to the power supply unit  10 . A coarse adjustment knob  14  may allow the user to choose between usable current level settings, such as a low current level (e.g 50-120 Amps) setting, as indicated by a low setting panel  16  and a high current level (e.g. 70-200 Amps) setting, as indicated by a high setting panel  18 . A rheostat  20  (e.g. a fine adjustment knob) may allow the user to fine tune the current output by varying the orientation of the rheostat  20  relative to a fine adjustment panel. For instance, there may be 10 settings on the rheostat  20  that each correspond to a single additional Amp that will be output (e.g. the first setting adds 1 additional Amp to the overall output, the second setting adds 2 additional Amps to the overall output, and so forth). Together, the coarse adjustment knob  14  and the rheostat  20  are configured to set the overall amperage output for the welding operation. For example, if the desired current output is 52 Amps, the coarse adjustment knob  14  may be set to 50 Amps, and the rheostat  20  may be set to output 2 Amps, achieving the overall output of 52 Amps. The user may need to adjust the coarse adjustment knob  14  and the rheostat  20  between welds since the desired overall output may be different for different processes. In some embodiments, the power supply unit  10  may be portable and may be communicatively coupled to additional system components, such as a wall power outlet, a battery, and so forth. 
         [0014]    In accordance with the present disclosure, the power supply unit  10  provides exemplary control panels  12  that allow the user to easily associate a chosen electrode with the correct coarse adjustment setting and the correct range of fine tuned settings to achieve the amperage setting recommended by the manufacturer for the chosen electrode.  FIG. 2  illustrates one such exemplary control panel  23  that includes a visually coded bar chart  24 , the coarse adjustment knob  14  with the high setting and the low setting options, which are indicated to the user by the low setting panel  16  and the high setting panel  18 , and the rheostat  20  with ten possible fine tuning settings on the fine tuning panel  22 . It should be noted that when the user sets the coarse adjustment knob  14  to a position pointing to the low setting panel  16  or the high setting panel  18 , internal components of the power supply unit  10  are configured to facilitate proper adjustment of the power supply  10  output. For example, in some embodiments, when the knob  14  is pointing to the high setting panel  18 , internal components of the power supply unit  10  output current at a higher amperage than when the knob  14  is pointing to the low setting panel  16 . 
         [0015]    The bar chart  24  informs the user of an optimal coarse adjustment knob  14  setting and an optimal rheostat  20  setting for a given electrode  26  with a given diameter  28  as described in more detail below. In the illustrated embodiment, visual references to electrodes A, B, and C with diameters D, E, F, and G are shown for descriptive purposes. However, one skilled in the art would understand that the electrode labels A, B and C may be any electrode models, such as 6010, 6011, 6013, 7018 and so forth, used in industrial practice. Similarly, diameters D, E, F and G are shown for explanatory purposes and may be any electrode diameter size, such as 3/32″, ⅛″, 5/32″, 3/16″ and so forth, used in industrial practice. Additionally, the illustrated amperage range from 1 to 10 corresponds to the 10 distinct positions in which the illustrated rheostat  20  may be placed. However, the ten markings are shown for descriptive purposes. In other embodiments, the rheostat  20  and the corresponding amperage range may contain more or less markings that represent smaller or larger amperage increments as the rheostat  20  is turned. 
         [0016]    The illustrated bar chart  24  includes a 10 by 12 grid in which each horizontal row corresponds to a particular electrode  26  and diameter  28  combination. For instance, the first row of the grid corresponds to electrode A and diameter D, the second row of the grid corresponds to electrode A and diameter E, and so forth. Each vertical column of the grid in the bar chart  24  corresponds to an amperage setting. For instance, the first vertical column corresponds to a 1 position setting, the second vertical column corresponds to a 2 position setting, and so forth. In the embodiment illustrated in  FIG. 2 , each horizontal row in the grid contains a shaded or hatched bar that is designed to convey two pieces of information to the user, the proper coarse adjustment knob  14  setting and the proper range of rheostat  20  settings for a given electrode with a given diameter. First, the shaded or hatched feature of the bar is configured to convey to the user whether to arrange the coarse adjustment knob  14  such that it lines up with the low setting panel  16  or the high setting panel  18  for a given electrode with a given diameter. This is indicated by the correspondence between the visual nature (e.g. patterned, colored, shaded, and so forth) of the low setting panel  16  and the visual nature of the bar. For instance, shaded bar  30 , associated with electrode A and diameter D, corresponds to a low setting  16  of the coarse adjustment knob  14 , as indicated by the correspondence between the shaded nature of the low setting panel  16  and the shaded nature of bar  30 . Similarly, shaded bar  32 , associated with electrode A and diameter E, corresponds to a low setting  16  of the coarse adjustment knob  14 , as indicated by the correspondence between the shaded nature of the low setting panel  16  and the shaded nature of bar  32 . Also, shaded bar  34 , associated with electrode A and diameter F, corresponds to a low setting  16  of the coarse adjustment knob  14 , as indicated by the correspondence between the shaded nature of the low setting panel  16  and the shaded nature of bar  34 . Additionally, shaded bar  36 , associated with electrode C and diameter D, corresponds to a low setting  16  of the coarse adjustment knob  14 , as indicated by the correspondence between the shaded nature of the low setting panel  16  and the shaded nature of bar  36 . 
         [0017]    The hatched nature of the high setting panel  18  of the coarse adjustment knob  14  may be used in the same manner. For instance, hatched bar  38 , associated with electrode A and diameter G, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  38 . Similarly, hatched bar  40 , associated with electrode B and diameter D, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  40 . Additionally, hatched bar  42 , associated with electrode B and diameter E, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  42 . Similarly, hatched bar  44 , associated with electrode B and diameter F, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  44 . Also, hatched bar  46 , associated with electrode B and diameter G, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  46 . Similarly, hatched bar  48 , associated with electrode C and diameter E, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  48 . Similarly, hatched bar  50 , associated with electrode C and diameter F, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  50 . Additionally, hatched bar  52 , associated with electrode C and diameter G, corresponds to a high setting  18  of the coarse adjustment knob  14 , as indicated by the correspondence between the hatched nature of the high setting panel  18  and the hatched nature of bar  52 . It should be noted that while the illustrated embodiment utilizes hatched and shaded visual features, other embodiments may utilize various different patterns, colors, and the like. 
         [0018]    With regards to the second piece of information that the bar conveys to the user, the location of the bar along an amperage range scale  54  corresponds to an optimal range of rheostat  20  settings to use with a particular electrode  26  and diameter  28 . For instance, for electrode A with diameter D, an indicated amperage range of 1 to 3 on the grid corresponds to a rheostat  20  setting between 1 and 3. Similarly, for electrode A with diameter E, an indicated amperage range of 3 to 6 on the grid corresponds to a rheostat  20  setting between 3 and 6. Similarly, for electrode A with diameter F, an indicated amperage range of 6 to 10 on the grid corresponds to a rheostat  20  setting between 6 and 10. Additionally, for electrode A with diameter G, an indicated amperage range of 5 to 8 on the grid corresponds to a rheostat  20  setting between 5 and 8. Similarly, for electrode B with diameter D, an indicated amperage range of 1 to 2 on the grid corresponds to a rheostat  20  setting between 1 and 2. Also, for electrode B with diameter E, an indicated amperage range of 3 to 5 on the grid corresponds to a rheostat  20  setting between 3 and 5. Similarly, for electrode B with diameter F, an indicated amperage range of 6 to 9 on the grid corresponds to a rheostat  20  setting between 6 and 9. Similarly, for electrode B with diameter G, an indicated amperage range of 9 to 10 on the grid corresponds to a rheostat  20  setting between 9 and 10. Similarly, for electrode C with diameter D, an indicated amperage range of 1 to 2 on the grid corresponds to a rheostat  20  setting between 1 and 2. Similarly, for electrode C with diameter E, an indicated amperage range of 3 to 6 on the grid corresponds to a rheostat  20  setting between 3 and 6. Similarly, for electrode C with diameter F, an indicated amperage range of 7 to 10 on the grid corresponds to a rheostat  20  setting between 7 and 10. Similarly, for electrode C with diameter G, an indicated amperage range of 10 on the grid corresponds to a rheostat  20  setting of 10. 
         [0019]    As described, the visually coded bar chart  24  therefore indicates the optimal coarse adjustment knob  14  setting and rheostat  20  setting to the user for a given electrode  26  with a given diameter  28 . It should be noted that in other embodiments, the color of the bar associated with a chosen electrode model  26  and diameter  28  may correspond to the color of the coarse adjustment knob  14  setting recommended by the electrode manufacturer. Additionally, other patterns and/or visual indicators may be used in place of the colors or the hatched/shaded nature of the bars. In some embodiments, a physical indicator and/or a visual indicator may be used to indicate a correspondence between a low setting panel  16  or a high setting panel  18  and the bars. For instance, raised patterns may be placed in each grid box to indicate a physical bar (i.e. to indicate amperage range 1-2, two raised dots may be placed in a horizontal row). 
         [0020]    The present disclosure provides methods that may be employed by a user to properly set the amperage setting on a control panel, such as panel  23 , in accordance with present embodiments.  FIG. 3  includes a process flow diagram that is representative of a procedure for optimally setting the coarse adjustment knob  14  and the rheostat  20  for a given electrode  26  with a given diameter  28  using the exemplary control panel  23  of  FIG. 2 . Each block in  FIG. 3  may represent a function or step. It should be noted that certain steps or functions may be performed in addition to those illustrated. Further, the illustrated functions or steps may be performed in a different order in accordance with present embodiments. 
         [0021]    Specifically, in the illustrated embodiment of  FIG. 3 , the user first turns the system on, as represented by block  56 , and chooses an electrode  26 , as represented by block  58 . The electrode  26  may be chosen by the user based on the parameters of the weld, such as the type of steel, the tensile strength of the workpiece, desired travel speed, and so forth. The user then finds the chosen electrode type  26  and diameter  28  on the chart, as represented by block  60 , matches the color on the chart  24  to the color on the course adjustment knob  14 , as represented by block  62 , and sets the coarse adjustment knob  14  accordingly, as represented by block  64 . In some embodiments, patterns or the like may be used in addition to or instead of colors. Subsequently, the user identifies the fine adjustment range suggested by the manufacturer for the given electrode  26  with a given diameter  28  from the chart  24 , as represented by block  66 , and sets the fine adjustment knob  20  accordingly, as represented by block  68 . The user may then weld, as represented by block  70 , adjusting the rheostat  20  within the range indicated by the bar associated with the given electrode  26  with the given diameter  28  as needed, as represented by block  72 . 
         [0022]      FIG. 4  illustrates an exemplary control panel  73  that allows the user to easily associate a chosen electrode with the correct coarse adjustment setting and the correct range of fine tuned settings to achieve the amperage setting recommended by the manufacturer for the chosen electrode. It should be noted that when the user sets the coarse adjustment knob  14  to a position pointing to the low setting panel  16  or the high setting panel  18 , internal components of the power supply unit  10  are configured to facilitate proper adjustment of the power supply  10  output. For example, when the knob  14  is pointing to the high setting panel  18 , internal components may output current at a higher amperage than when the knob  14  is pointing to the low setting panel  16 . In the illustrated embodiment, the control panel  73  includes the coarse adjustment knob  14  with the high setting panel  18  and the low setting panel  16  and the rheostat  20  with ten possible fine tuning settings as represented by the numbers  1  through  10  on the fine adjustment panel  22 . In the illustrated embodiment, there are three stick electrode types with associated diameters called out for each of the two coarse adjustment knob  14  setting panels  16 ,  18  for explanatory purposes. In other embodiments, more or less electrodes with associated diameters may be called out as desired. For example, additional electrode models, such as 6011, 6013 and so forth, may be called out on additional panels in certain embodiments. Similarly, additional diameters, such as 3/16″, may be called out on additional panels in certain embodiments. 
         [0023]    In the illustrated embodiment, a first panel  74  of the low setting panel  16  contains an icon  76 , which indicates that for a 6010 electrode with a 3/32″ diameter, the user should set the rheostat  20  to a 2 position. Additionally, the icon  76  contains a curved arrow  78  that graphically indicates to the user a range (1-4) of rheostat  20  settings that may be used with the 6010 electrode with a 3/32″ diameter. Indeed, the arrow  78  is positioned relative to a circle component of the icon  76  such that there is a correspondence between the relative positioning of the arrow  78  with respect to the circle and positioning of the rheostat  20  to achieve the proper setting. Similarly, in the illustrated embodiment, a second panel  80  of the low setting panel  16  contains an icon  82 , which indicates that for a 6010 electrode with a ⅛″ diameter, the user should set the rheostat  20  at a 9 position. Additionally, the icon  82  contains a curved arrow  84  that graphically indicates to the user a range (2-10) of rheostat  20  settings that may be used with the 6010 electrode with a ⅛″ diameter. Similarly, in the illustrated embodiment, a third panel  86  of the low setting panel  16  contains an icon  88 , which indicates that for a 7018 electrode with a 3/32″ diameter, the user should set the rheostat  20  at an 8 position. Additionally, the icon  88  contains a curved arrow  90  that graphically indicates to the user a range (2-10) of rheostat  20  settings that may be used with the 7018 electrode with a 3/32″ diameter. In some embodiments, the curved arrows  78 ,  84 , and  90  may also include numbers on each end that indicate the associated range. 
         [0024]    The high setting panel  18  of the coarse adjustment knob  14  may be used in much the same way as the low setting  16 . In the illustrated embodiment, a first panel  92  of the high setting panel  18  contains an icon  94 , which indicates that for a 7018 electrode with a ⅛″ diameter, the user should set the rheostat  20  to a 3 position. Additionally, the icon  94  contains a curved arrow  96  that graphically indicates to the user a range (1-5) of rheostat  20  settings that may be used with the 7018 electrode with a ⅛″ diameter. Similarly, in the illustrated embodiment, a second panel  98  of the high setting panel  18  contains an icon  100 , which indicates that for a 6010 electrode with a 5/32″ diameter, the user should set the rheostat  20  at a 3 position. Additionally, the icon  100  contains a curved arrow  102  that graphically indicates to the user a range (1-8) of rheostat  20  settings that may be used with the 6010 electrode with a 5/32″ diameter. Similarly, in the illustrated embodiment, a third panel  104  of the high setting panel  18  contains an icon  106 , which indicates that for a 7018 electrode with a 5/32″ diameter, the user should set the rheostat  20  at a 7 position. Additionally, the icon  106  contains a circular arrow  108  that graphically indicates to the user a range (3-9) of rheostat  20  settings that may be used with the 7018 electrode with a 5/32″ diameter. Again, in some embodiments, curved arrows may also include numbers on each end that indicate the associated range. 
         [0025]      FIG. 5  illustrates exemplary methods that may be employed by the user to properly set the amperage output with the illustrated exemplary control panel  73  of  FIG. 4 . In particular,  FIG. 5  illustrates exemplary logic that may be used for optimally setting the coarse adjustment knob  14  and the rheostat  20  for a given electrode  26  with a given diameter  28  using the exemplary control panel  73  of  FIG. 4 . Each block in  FIG. 5  may represent a function or step. First, in the illustrated embodiment, the user turns the system on, as represented by block  56 , and chooses an electrode  26 , as represented by block  58 . The electrode  26  may be chosen by the user based on the parameters of the weld, such as the type of steel, the tensile strength of the workpiece, desired travel speed, and so forth. The user then finds the electrode type  26  and diameter  28  on the coarse adjustment knob  14  panels, as represented by block  110  and sets the coarse adjustment knob  14  to the low setting  16  or the high setting  18  accordingly, as represented by block  64 . Subsequently, the user identifies the fine adjustment setting suggested by the manufacturer for the given electrode  26  with a given diameter  28  from the icon on the panel, as represented by block  112 , and sets the fine adjustment knob  20  accordingly, as represented by block  68 . The user may then weld, as represented by block  70 , adjusting the rheostat  20  as needed within the range indicated by the curved arrow above the icon associated with the given electrode  26  with the given diameter  28 , as represented by block  72 . 
         [0026]    While only certain features of the present disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure.