WELDING POWER SUPPLIES AND USER INTERFACES FOR WELDING POWER SUPPLIES

Welding power supplies and user interfaces for welding power supplies are disclosed. An example welding-type system includes a wire feeder and a welding-type power supply having a graphical user interface (GUI) that includes a first graphical interface representing a first welding parameter, and a second graphical interface representing a second welding parameter. A controller receives data corresponding to output values for each of the first and second welding parameters, respectively. The controller receives an output value associated with the second welding parameter and calculates a range of values for each of the first and second welding parameter based on the received second welding parameter output value and one or more corresponding welding process parameters. First and second graphical bands representing the range of values for a respective welding parameter are generated and displayed.

BACKGROUND

This disclosure relates generally to welding systems and, more particularly, to welding power supplies and user interfaces for welding power supplies.

Myriad interface types have been used for conventional power supplies. Conventional user interface for power supplies either rely on the operator to manually select the appropriate parameters, such as voltage and wire feed speed, or rely on the operator specifying the material thickness and then calculating appropriate parameters from the material thickness.

SUMMARY

Welding power supplies and user interfaces for welding power supplies are disclosed, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims.

DETAILED DESCRIPTION

Disclosed example power supplies, user interfaces, and methods allow for simple and intuitive user setup of a welding power source and/or wire feeder.

Example welding power supplies and user interfaces for welding power supplies are disclosed. An example welding-type system includes a wire feeder and a welding-type power supply having a graphical user interface (GUI) that includes a first graphical interface representing a first welding parameter, and a second graphical interface representing a second welding parameter. A controller receives data corresponding to output values for each of the first and second welding parameters, respectively. The controller receives an output value associated with the second welding parameter and calculates a range of values for each of the first and second welding parameter based on the received second welding parameter output value and one or more corresponding welding process parameters. First and second graphical bands representing the range of values for a respective welding parameter are generated and displayed.

When adjusting the wire feed speed, the display may provide a recommended material thickness or range of thicknesses based on the wire feed speed. As the wire feed speed is adjusted, the voltage value and/or range is automatically adjusted as well based on stored voltage-wire feed speed relationships and selected parameters (such as workpiece thickness). However, the operator can also manually adjust the voltage to achieve the desired welding performance independent of the wire feed speed, for example. Indicators, such as LEDs having shapes such as small arrows and a star, next to the voltage display indicate whether the setting is at the default or preferred range or voltage (e.g., a star), higher than the preferred voltage or range (up arrow), or lower than the preferred voltage or range (down arrow).

The initial selection process of the weld process, electrode wire type, electrode wire size, and shielding gas composition can assist the user to select a preferred (e.g., optimal) set of weld parameters. The selection of the weld process, electrode wire type, electrode wire size, and shielding gas composition is achieved by repeatedly pressing a corresponding button to cycle through a sequence of permissible values for the corresponding parameter.

In disclosed examples, a graphical user interface includes a first graphical interface representing a first welding parameter and a second graphical interface representing a second welding parameter, each graphical interface being controlled by a controller. The controller is configured to receive data corresponding to output values for each of the first and second welding parameters, respectively. The controller displays a first marker on the first graphical interface representing the output value associated with the first welding parameter, displays a second marker on the second graphical interface representing the output value associated with the second welding parameter. The controller may determine a range of values for each of the first and second welding parameter based on the output value associated with the second welding parameter and one or more corresponding welding process parameters, generate a first graphical band representing the range of values for the first welding parameter, and generate a second graphical band representing the range of values for the second welding parameter. The controller further displays the first and second graphical bands on the first and second graphical interfaces, respectively.

In some examples, the controller is further configured to adjust a position of the first graphical band on the first graphical interface based on a change in the output value associated with the second welding parameter.

In examples, the generated range of values for the second welding parameter are a first range of values, the controller further configured to determine a change in the output value associated with the second welding parameter from a first value corresponding to a first workpiece property value to a second value corresponding to a second workpiece property value.

In some examples, the first workpiece property value corresponds to the first range of values and the second workpiece property value corresponds to a second range of values, the controller further configured to generate a third graphical band corresponding to the second range of values; and display the third graphical band on the second graphical interface.

In examples, the second graphical band representing the first range of values overlaps with the third graphical band representing the second range of values.

In some examples, the controller is further configured to access a list of workpiece properties, each property corresponding to a range of values for the first or the second welding parameter.

In examples, the controller is further configured to receive an input corresponding to a change in value of the first welding parameter; display the first marker at the changed value on the first graphical interface independently of the first graphical band.

In some examples, the controller is further configured to display a first characteristic on a first portion of each graphical band associated with a low welding parameter value; and display a second characteristic on a second portion of the graphical representation associated with a high welding parameter value.

In examples, the first or second characteristic comprises one of a color, an intensity, a shape, a size, or a pattern. In some examples, the first characteristic is a first color and the second characteristic is a second color, the controller configured to control the respective graphical interface to display a color gradient from the first color to the second color.

In some examples, portions of each graphical interface displays a graphical operating range corresponding to the operating range of the respective welding parameter, wherein portions of the graphical operating range outside the respective graphical band is displayed with a third characteristic.

In examples, the controller is further configured to dynamically calculate the range of values based on a change in the property of the workpiece. In some examples, the property of the workpiece comprises one or more of material thickness or material type.

In disclosed examples, a welding-type system includes a wire feeder and a welding-type power supply. The welding-type power supply includes a graphical user interface (GUI) that includes a first graphical interface representing a first welding parameter, and a second graphical interface representing a second welding parameter and a controller. The controller receives data corresponding to output values for each of the first and second welding parameters, respectively. An output value associated with the second welding parameter is received from a user interface. A range of values are calculated for each of the first and second welding parameters based on the received second welding parameter output value and one or more corresponding welding process parameters. A first graphical band representing the range of values for the first welding parameter and a second graphical band representing the range of values for the second welding parameter are generated by the controller. And the first and second graphical bands on the first and second graphical interfaces are displayed, respectively.

In some examples, each graphical interface further comprises a numerical value of the respective welding parameter. In examples, the first welding parameter is voltage, and the second welding parameter is wire feed speed. In some examples, one or more visual indicators associated with the first or second graphical band is changed in response to a change in the first or the second welding parameter.

In examples, the one or more visual indicators is one of a color, a brightness, a shape, a size, or a pattern. In some examples, the controller is further configured to display a position of a value marker associated with the first or second welding parameter on the respective graphical interface independently of the respective graphical band.

In examples, limits of the operating ranges the first and second graphical interfaces correspond to operating parameters of the welding-type system, the controller further configured to display the first and second visual bands within the respective operating range based on the calculated range of values.

As used herein, the term “welding program” includes at least a set of welding parameters for controlling a weld. A welding program may further include other software, algorithms, processes, or other logic to control one or more welding-type devices to perform a weld.

Turning now to the drawings,FIG. 1Ais a block diagram of an example welding system100having a welding-type power supply102, a wire feeder104, and a welding torch106. The welding system100powers, controls, and supplies consumables to a welding application. In some examples, the power supply102directly supplies input power to the welding torch106. The welding torch106may be a torch configured for shielded metal arc welding (SMAW, or stick welding), tungsten inert gas (TIG) welding, gas metal arc welding (GMAW), flux cored arc welding (FCAW), based on the desired welding application. In the illustrated example, the power supply102is configured to supply power to the wire feeder104, and the wire feeder104may be configured to route the input power to the welding torch106. In addition to supplying an input power, the wire feeder104may supply a filler metal to a welding torch106for various welding applications (e.g., GMAW welding, flux core arc welding (FCAW)). While the example system100ofFIG. 1Aincludes a wire feeder104(e.g., for GMAW or FCAW welding), the wire feeder104may be replaced by any other type of remote accessory device, such as a stick welding and/or TIG welding remote control interface that provides stick and/or TIG welding

The power supply102receives primary power108(e.g., from the AC power grid, an engine/generator set, a battery, or other energy generating or storage devices, or a combination thereof), conditions the primary power, and provides an output power to one or more welding devices in accordance with demands of the system100. The primary power108may be supplied from an offsite location (e.g., the primary power may originate from the power grid). The power supply102includes power conversion circuitry110, which may include transformers, rectifiers, switches, and so forth, capable of converting the AC input power to AC and/or DC output power as dictated by the demands of the system100(e.g., particular welding processes and regimes). The power conversion circuitry110converts input power (e.g., the primary power108) to welding-type power based on a weld voltage setpoint and outputs the welding-type power via a weld circuit.

In some examples, the power conversion circuitry110is configured to convert the primary power108to both welding-type power and auxiliary power outputs. However, in other examples, the power conversion circuitry110is adapted to convert primary power only to a weld power output, and a separate auxiliary converter111is provided to convert primary power to auxiliary power. In some other examples, the power supply102receives a converted auxiliary power output directly from a wall outlet. Any suitable power conversion system or mechanism may be employed by the power supply102to generate and supply both weld and auxiliary power.

The power supply102includes a control circuitry112to control the operation of the power supply102. The power supply102also includes a user interface114. The control circuitry112receives input from the user interface114, through which a user may choose a process and/or input desired parameters (e.g., voltages, currents, particular pulsed or non-pulsed welding regimes, and so forth). The user interface114may receive inputs using one or more input devices115, such as via a keypad, keyboard, physical buttons, a touch screen (e.g., software buttons), a voice activation system, a wireless device, etc. Furthermore, the control circuitry112controls operating parameters based on input by the user as well as based on other current operating parameters. Specifically, the user interface114may include a display116for presenting, showing, or indicating, information to an operator. The control circuitry112may also include interface circuitry for communicating data to other devices in the system100, such as the wire feeder104. For example, in some situations, the power supply102wirelessly communicates with other welding devices within the welding system100. Further, in some situations, the power supply102communicates with other welding devices using a wired connection, such as by using a network interface controller (NIC) to communicate data via a network (e.g., ETHERNET, 10baseT, 10base100, etc.). In the example ofFIG. 1A, the control circuitry112communicates with the wire feeder104via the weld circuit via a communications transceiver118, as described below.

The control circuitry112includes at least one controller or processor120that controls the operations of the power supply102. The control circuitry112receives and processes multiple inputs associated with the performance and demands of the system100. The processor120may include one or more microprocessors, such as one or more “general-purpose” microprocessors, one or more special-purpose microprocessors and/or ASICS, and/or any other type of processing device. For example, the processor120may include one or more digital signal processors (DSPs).

The example control circuitry112includes one or more storage device(s)123and one or more memory device(s)124. The storage device(s)123(e.g., nonvolatile storage) may include ROM, flash memory, a hard drive, and/or any other suitable optical, magnetic, and/or solid-state storage medium, and/or a combination thereof. The storage device123stores data (e.g., data corresponding to a welding application), instructions (e.g., software or firmware to perform welding processes), and/or any other appropriate data. Examples of stored data for a welding application include an attitude (e.g., orientation) of a welding torch, a distance between the contact tip and a workpiece, a voltage, a current, welding device settings, and so forth.

The memory device124may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device124and/or the storage device(s)123may store a variety of information and may be used for various purposes. For example, the memory device124and/or the storage device(s)123may store processor executable instructions125(e.g., firmware or software) for the processor120to execute. In addition, one or more control regimes for various welding processes, along with associated settings and parameters, may be stored in the storage device123and/or memory device124, along with code configured to provide a specific output (e.g., initiate wire feed, enable gas flow, capture welding current data, detect short circuit parameters, determine amount of spatter) during operation. One or more lists or look up tables may be provided, and/or network connections to various databases available to inform decision-making.

In some examples, the welding power flows from the power conversion circuitry110through a weld cable126to the wire feeder104and the welding torch106. The example weld cable126is attachable and detachable from weld studs at each of the power supply102and the wire feeder104(e.g., to enable ease of replacement of the weld cable126in case of wear or damage). Furthermore, in some examples, welding data is provided with the weld cable126such that welding power and weld data are provided and transmitted together over the weld cable126. The communications transceiver118is communicatively coupled to the weld cable126to communicate (e.g., send/receive) data over the weld cable126. The communications transceiver118may be implemented using serial communications (e.g., full-duplex RS-232 or RS-422, or half-duplex RS-485), network communications (e.g., Ethernet, PROFIBUS, IEEE 802.1X wireless communications, etc.), parallel communications, and/or any other type of communications techniques. In some examples, the communications transceiver118may implement communications over the weld cable126.

The example communications transceiver118includes a receiver circuit121and a transmitter circuit122. Generally, the receiver circuit121receives data transmitted by the wire feeder104via the weld cable126and the transmitter circuit122transmits data to the wire feeder104via the weld cable126. The communications transceiver118enables remote configuration of the power supply102from the location of the wire feeder104, and/or command and/or control of the wire feed speed output by the wire feeder104and/or the weld power (e.g., voltage, current) output by the power supply102.

The example wire feeder104also includes a communications transceiver119, which may be similar or identical in construction and/or function as the communications transceiver118. While communication over a separate communications cable is illustrated inFIG. 1A, other communication media, such as wireless media, power line communications, and/or any other communications media, may be used.

In some examples, a gas supply128provides shielding gases, such as argon, helium, carbon dioxide, and so forth, depending upon the welding application. The shielding gas flows to a valve130, which controls the flow of gas, and if desired, may be selected to allow for modulating or regulating the amount of gas supplied to a welding application. The valve130may be opened, closed, or otherwise operated by the control circuitry112to enable, inhibit, or control gas flow (e.g., shielding gas) through the valve130. Shielding gas exits the valve130and flows through a cable132(which in some implementations may be packaged with the welding power output) to the wire feeder104, which provides the shielding gas to the welding application. In some examples, the welding system100does not include the gas supply128, the valve130, and/or the cable132.

In some examples, the wire feeder104uses the welding power to power the various components in the wire feeder104, such as to power a wire feeder controller134. As noted above, the weld cable126may be configured to provide or supply the welding power. The power supply102may also communicate with a communications transceiver119of the wire feeder104using the weld cable126and the communications transceiver118disposed within the power supply102. In some examples, the communications transceiver119is substantially similar to the communications transceiver118of the power supply102. The wire feeder controller134controls the operations of the wire feeder104. In some examples, the wire feeder104uses the wire feeder controller134to detect whether the wire feeder104is in communication with the power supply102and to detect a current welding process of the power supply102if the wire feeder104is in communication with the power supply102.

A contactor135(e.g., high amperage relay) is controlled by the wire feeder controller134and configured to enable or inhibit welding power to continue to flow to the weld cable126for the welding application. In some examples, the contactor135is an electromechanical device. However, the contactor135may be any other suitable device, such as a solid-state device. The wire feeder104includes a wire drive136that receives control signals from the wire feeder controller134to drive rollers138that rotate to pull wire off a spool140of wire. The wire is provided to the welding application through a torch cable142. Likewise, the wire feeder104may provide the shielding gas from the cable132through the cable142. The electrode wire, the shield gas, and the power from the weld cable126are bundled together in a single torch cable144and/or individually provided to the welding torch106. In some examples, the contactor135is omitted and power is initiated and stopped by the power supply102. In some examples, one or more sensors127are included with or connected to in the wire feeder102to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to inform the controller134during the welding process. In some examples, one or more sensors are included in the welding power supply102.

The welding torch106delivers the wire, welding power, and/or shielding gas for a welding application. The welding torch106is used to establish a welding arc between the welding torch106and a workpiece146. A work cable148couples the workpiece146to the power supply102(e.g., to the power conversion circuitry110) to provide a return path for the weld current (e.g., as part of the weld circuit). The example work cable148attachable and/or detachable from the power supply102for ease of replacement of the work cable148. The work cable148may be terminated with a clamp150(or another power connecting device), which couples the power supply102to the workpiece146. In some examples, one or more sensors147are included with or connected to the welding torch106to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to inform the controller134and/or112during the welding process.

FIG. 1Bis a schematic diagram of another example welding system152in which the wire feeder104includes the user interface114in addition or as an alternative to the user interface on the welding power supply102. In the example ofFIG. 1B, the control circuitry134of the wire feeder104implements the determinations of the welding program and welding parameters which are described with reference to the control circuitry112ofFIG. 1A.

FIG. 1Cis a schematic diagram of another example welding system154including a separate user interface156. The user interface156is a separate device, and may be connected to the welding power supply102and/or to the wire feeder104to provide commands and/or control information. The example user interface156includes the input devices115and the display116, and includes control circuitry158. The example control circuitry158includes the processor(s)120and the memory124storing the instructions125. The example user interface156further includes a communications transceiver119to enable communications between the user interface156and the welding power supply102and/or the wire feeder. AlthoughFIGS. 1A-1Care illustrated as having a user interface (114,156) incorporated with a particular system, the illustration is exemplary such that one or more of the interfaces disclosed herein as well as additional user interfaces may be incorporated in one or more of the example welding systems disclosed herein.

FIG. 2illustrates an example graphical user interface200that may be used to implement the graphical user interface(s)114,156ofFIGS. 1A-1C. The graphical user interface200ofFIG. 2includes one or more graphical interfaces202and204, one or more welding property displays230, and/or one or more selectors232and234to allow a user to configure one or more welding parameters for a selected weld process. The graphical user interface200may include more or fewer of the example graphical interfaces202,204illustrated inFIG. 2.

The example welding system(s) may implement a synergic mode, in which the control circuitry112, controller134, and/or controller158, determines a voltage value in response to a wire feed speed selection via selector234and a predetermined relationship between the wire feed speed and the voltage. In some examples, the predetermined relationship is selected based on the weld program or one or more welding parameters, including workpiece type, thickness, etc. The control circuitry/controller may enable or disable the synergic mode based on the selected weld program (e.g., based on a selection of synergic weld process or a non-synergic weld process).

When the control circuitry/controller implements the synergic mode, the control circuitry/controller may determine a workpiece or material thickness that is recommended for the currently-selected wire feed speed and/or weld program. For example, a range of wire feed speeds may be stored as a list of values associated with one or more welding parameters (e.g., voltage, current, workpiece properties) in the storage device(s)123and/or the memory124as suitable for a particular weld program and wire feed speed.

The example user interface200ofFIG. 2for synergically adjusting voltage and wire feed speed illustrates a wire feed speed of 375 inches per minute (IPM) selected (e.g., via the selector234, via the control circuitry/controller, etc.) and is displayed on the graphical interface204. Based on the selected wire feed speed, the control circuitry/controller determines the corresponding voltage associated with the weld program and/or one or more of the welding process parameter, workpiece property, the wire type parameter, the wire size parameter, or the gas type parameter based on a relationship between at least the wire feed speed and the voltage, all of which may be stored (e.g., in the storage device(s)123, in the memory124, etc.) in a list of values or look up table for instance. The control circuitry/circuit sets the voltage value determined based on the relationship.

In addition to setting the voltage, the example control circuitry/controller determines a recommended material thickness corresponding to the selected wire feed speed (or vice versa), and displays the material thickness on the display230. In addition to the wire feed speed, the control circuitry/controller may determine the material thickness based on the weld process parameter, the wire type parameter, the wire size parameter, and/or the gas type parameter. As illustrated inFIG. 2, a wire feed speed of 375 IPM results in a voltage value of 22.5 volts and a material thickness of ¼″. As illustrated inFIGS. 3A and 3B, changing the wire feed speed results in a change in the voltage value, and may cause a change in recommended material thickness.

The graphical user interface200includes a first graphical interface202representing a first welding parameter, such as voltage. A second graphical interface204represents a second welding parameter, such as wire feed speed. Each graphical interface202and204may be controlled by a controller, such as control circuitry112, controller134, and/or controller158, responsive to selectors232and234, for example.

Each graphical interface202and204includes a marker206,218representing the output value associated with the respective welding parameter (e.g., voltage or wire feed speed). During a welding process, each graphical interface202and204may display a numerical value216,229corresponding to the welding system output of the particular welding parameter, such as measured from one or more sensors. In some examples, the numerical values216,229represent an estimated or calculated value.

Each graphical interface202and204includes a graphical operating range208,222representing the full operating range of output values for the particular welding parameter (e.g., based on the particular welding power source). Within each operating range is a graphical band210,224providing a visual representation of the value ranges for each of the first and second welding parameter based on one or more of a welding parameter output value (e.g., the wire feed speed) and/or associated with the weld program and/or one or more of the welding process parameter, workpiece property, the wire type parameter, the wire size parameter, or the gas type parameter. For example, the welding property display230may provide a numerical value (e.g., a material gauge or thickness) or other information (e.g., material type) corresponding to a selected and/or calculated property of the workpiece. In some examples, the display230may provide additional or alternative information regarding one or more welding process parameters.

The graphical bands210,224represent a recommended range of operating values associated with a particular material property and/or welding process parameter. In the example of graphical interface202, graphical band210represents a range of values spanning a low voltage value (identified by a darker grey in portion214) to a high voltage value (identified by a lighter grey in portion212) corresponding to a recommended range of voltage values associated with a ¼ inch workpiece. In the example ofFIG. 2, marker206(representing approximately 22.5 volts as shown in central block216) is approximately centered on the graphical band210between lower portion214and higher portion212. Marker218, corresponding to the wire feed speed value shown in central block229, is positioned within graphical band224slightly right of center, thus at a portion226of the graphical band224associated with a higher wire feed speed, versus portion228representing a lower wire feed speed.

As shown, portions214,228represent a lower value for the respective welding parameters. InFIG. 2, this is illustrated as a dark grey, whereas portions212,226, representing higher values for the respective welding parameters, are illustrated as a lighter grey. The gradient between dark and light provides an observer with an immediate indicator that a particular welding parameter is at the low or high end of the range of values. Although illustrated as shades of grey, in disclosed examples, the gradient can be displayed as different colors, patterns, shapes, intensities, to name but a few. Additionally or alternatively, values may be displayed to provide a numerical indicator as to the limits of the operative range. Further, within each graphical band, the range of values may be represented by colors, for instance, with lower or cooler values corresponding to blue and higher or hotter values corresponding to red.

In some examples, the particular values, ranges, and/or adjustments displayed in the graphical user interface200are calculated by the controller and/or control circuitry. For example, the controller is configured to receive data corresponding to output values for each of the first and second welding parameters, such as via a user input and/or measured data from one or more sensors. The controller further calculates the ranges of values for each of the welding parameter based on one or more inputs, including welding parameter output values, one or more of the welding process parameters, and/or a property of the workpiece property.

The controller may be configured to access a list of workpiece properties, each property corresponding to a range of values for a selected welding parameter, such that when a workpiece property is known, the range of values corresponding to the graphical bands is identified from the list. Additionally or alternatively, the controller may access a list of workpiece properties associated with one or more welding parameters, such as wire feed speed, and/or welding process parameters. Thus, if a user input selects a particular wire feed speed, the controller identifies a corresponding workpiece property (such as gauge or thickness). This information can then be used to determine the range of values for one or more of the welding parameters.

Although not illustrated inFIG. 2, other visual indicators may be provided in the graphical interface200. For example, historical information may be provided as to what types of material and/or welding parameter ranges have been used may be displayed. A visual characteristic (such as color) may be displayed with the graphical interfaces, such as reflecting the characteristic associated with the respective marker's position within a graphical band.

Further, the controller may calculate trending information during the welding process, such that the controller can anticipate a shift to a different material thickness, for instance. For example, the display230may indicate whether a particular welding parameter (wire feed speed) is approaching a threshold to a larger or smaller gauge material. The indicators can include arrows, text, colors, a change in character of the displayed material property, to name a few.

FIGS. 3A and 3Billustrate an implementation of the graphical user interface200in response to a change in one or more of the welding parameters. For instance, selector234may be turned in a direction238to increase the wire feed speed, as indicated inFIG. 2. In the example ofFIG. 3A, the wire feed speed increases from 375 to 380 inches per minute (IPM). As shown, the marker208is now at an edge of the portion226of band224, indicating the wire feed speed is at the upper threshold of the range of values associated with ¼ inch material thickness.

As shown inFIG. 3B, the wire feed speed increases to 381, which causes the controller to determine the wire feed speed has entered into a new range of values corresponding to a new graphical band225. Display231has transitioned to reflect a 5/16 inch material thickness, and the voltage output value has increased from 22.5 to 23, and ultimately to 26.4 to correspond to a voltage level determined by the controller to be suitable for a welding process on a 5/16 inch workpiece.

As shown inFIG. 3B, although graphical band224(corresponding to ¼ inch material) has transitioned to graphical band225(corresponding to 5/16 inch material), a degree of overlap exists between the two bands. However, in some examples, a given range of values (and the associated band) will be defined by a high threshold value corresponding to a low threshold value of another range of values (associated with another band).

The graphical user interface200enables an operator to easily and intuitively set up (or configure) a type of weld process. The example graphical user interface200may include a weld voltage parameter selector232and/or a wire feed speed selector234. The example selectors are shown inFIG. 2and described as hardware knobs, but may be implemented using other types of input devices, such as software buttons executed on a touch screen or other display, switches, and/or any other type of input device. The operator may, after the voltage is set by the controller in response to a selected wire feed speed in synergic mode, adjust the voltage via the voltage adjustment knob232.

FIG. 4illustrates an example graphical user interface400, which associates arc length with wire feed speed. As shown, a graphical interface402incorporates features similar to those of graphical interface204. In particular, a range of values are represented as408, with a graphical band410illustrating a range of values associated with the material property displayed at230and/or the wire feed speed as shown in graphical interface204. Accordingly, a value associated with arch length is centrally displayed at416within graphical interface402as marker406indicates where the arc length value416corresponds to the range of values shown in graphical band410. Thus, portion414(in dark grey) indicates a shorter arc length, whereas portion412(in light grey) indicates a longer arc length.

The arc length graphical interface402can be controlled by a selector, similar to selector232. The arc length selection enables the operator to adjust the feel of the arc within a range between “shorter” and more “long.” The example arc length may be implemented using an encoder to determine the position of the arc length selector, which enables rapid recall and setting of prior values of one or more welding parameters that are associated with the arc length parameter.

FIG. 5illustrates an example graphical user interface500, which includes two bands on each graphical interface502,504. For example, graphical interface502corresponds to voltage similar to graphical interface202shown inFIG. 2. Graphical interface502includes two operational ranges508,509, each with a band510,511corresponding to a different material property (e.g., thickness) and/or welding parameter (e.g., wire feed speed). As disclosed herein, ranges of values represented in each band510,511may overlap; however, in some examples, a threshold value indicates the end of a given range of values and the beginning of another range of values.

Graphical interface504illustrates a similar concept, such that operational ranges522,523show different range of values represented in bands524,525. As shown, graphical bands510,524may correspond to a first material property (e.g., a ¼ inch workpiece), whereas graphical bands511,525may correspond to a second material property (e.g., a ⅜ inch workpiece).

In some examples, as wire feed speed increases, the associated values and position of the marker508increases accordingly. As the wire feed speed meets the threshold for the current material thickness, the change in material thickness setting may be displayed, such as within display530and/or indicated by a marker532. Moreover, as the range of values are recalculated, the selected band may reflect the change, such as providing visual emphasis (e.g., intensity, color change, shape, pattern, etc.).

As is further shown inFIG. 5, display530illustrates an example technique to indicate a range of material properties in a different format. For example, text corresponding to various workpiece thicknesses may be provided along a dial, where the ranges may change and/or the indicator532may change in response to a selected change in wire feed speed.

In some examples, an additional or alternative indicator ring may be displayed outside the graphical interfaces (e.g.,202,204,402,502,504). The indicator ring may represent material thickness as a static or dynamic image, which corresponds to movement of the respective welding parameter value and/or marker.

FIG. 6is a flowchart representative of example machine readable instructions600which may be executed by the example welding system100ofFIG. 1A, the example welding system152ofFIG. 1B, and/or the example welding system154ofFIG. 1C, to configure one or more graphical user interfaces during a welding process. The example instructions600may be stored in the storage device(s)123and/or the memory124and executed by the processor(s)120of the control circuitry112. The example instructions600are described below with reference to the example graphical user interfaces200,400and500ofFIGS. 2 through 5.

In block602, a first graphical interface is displayed representing a first welding parameter (e.g., voltage). In block604, a second graphical interface is displayed representing a second welding parameter (e.g., wire feed speed), each graphical interface being controlled by a controller. In block606, the controller receives data corresponding to output values for each of the first and second welding parameters, respectively. For example, the output values can be measured by one or more sensors, calculated by the controller, and/or reflect a selected value (e.g., from selectors232,234).

In block608, a first marker is displayed on the first graphical interface representing the output value associated with the first welding parameter. In block610, a second marker is displayed on the second graphical interface representing the output value associated with the first welding parameter.

In block612, the controller is configured to calculate a range of values for each of the first and second welding parameter based on the output value associated with the second welding parameter and/or associated with the weld program and/or one or more of the welding process parameter, the wire type parameter, the wire size parameter, the gas type parameter, or a corresponding workpiece property (e.g., material thickness, material type, welding process, etc.). Based on the calculated range of values, a first graphical band is generated to represent the range of values for the first welding parameter in block614. A second graphical band is generated to represent the range of values for the second welding parameter in block616.

In block618, the controller displays a first characteristic on a first portion of each graphical band associated with a low welding parameter value and displays a second characteristic on a second portion of the graphical representation associated with a high welding parameter value. In block620, the first and second graphical bands are displayed on the first and second graphical interfaces, respectively.

In block622, the controller monitors the first and second welding parameters (via sensors, user inputs, etc.), and determines in block624if there is a change to one or more of the first and second welding parameters.

If there is a change in value to the second welding parameter (e.g., the wire feed speed), the controller compares the change to the range of values in block626. If the change in value is within the range of values, the marker position is adjusted accordingly in block628, but the range of values (and the relevant graphical band) remains unchanged.

If the change in value is beyond the range of values (and thus the graphical band), the method determines the workpiece property that corresponds to the output value in block630. In some examples, the method additionally or alternatively determines one or more of the welding process parameter, the wire type parameter, the wire size parameter, or the gas type parameter. In some examples, the controller determines whether the range of values is determined via an algorithm (e.g., based on programed values) or via a list of values in block632. If an algorithm is employed, the method proceeds to block634to calculate a new range of values for one or both of the first and second welding parameters based on the workpiece property.

If a list of values is referenced, the method proceeds to block636to access a list of workpiece properties and/or welding process parameters, each property corresponding to a range of values for the first or the second welding parameter. In block638, a range of values associated with the workpiece property value is identified. Based on the updated second range of values, in block640an updated third graphical band is generated and displayed for one or both of the first and second welding parameters.

The present devices and/or methods may be realized in hardware, software, or a combination of hardware and software. The present methods and/or systems may be realized in a centralized fashion in at least one computing system, processors, and/or other logic circuits, or in a distributed fashion where different elements are spread across several interconnected computing systems, processors, and/or other logic circuits. Any kind of computing system or other apparatus adapted for carrying out the methods described herein is suited. A typical combination of hardware and software may be a processing system integrated into a welding power supply with a program or other code that, when being loaded and executed, controls the welding power supply such that it carries out the methods described herein. Another typical implementation may comprise an application specific integrated circuit or chip such as field programmable gate arrays (FPGAs), a programmable logic device (PLD) or complex programmable logic device (CPLD), and/or a system-on-a-chip (SoC). Some implementations may comprise a non-transitory machine-readable (e.g., computer readable) medium (e.g., FLASH memory, optical disk, magnetic storage disk, or the like) having stored thereon one or more lines of code executable by a machine, thereby causing the machine to perform processes as described herein. As used herein, the term “non-transitory machine readable medium” is defined to include all types of machine readable storage media and to exclude propagating signals.

The control circuitry may identify welding conditions of a given weld and automatically find the optimum value of rate of current rise for the welding conditions. An example control circuit implementation may be an Atmel Mega16 microcontroller, a STM32F407 microcontroller, a field programmable logic circuit and/or any other control or logic circuit capable of executing instructions that executes weld control software. The control circuit could also be implemented in analog circuits and/or a combination of digital and analog circuitry. Examples are described herein with reference to an engine-driven stick welder, but may be used or modified for use in any type of high frequency switching power source.