Systems and methods for automated cleaning of wire electrodes after welding

Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

TECHNICAL FIELD

The present disclosure generally relates to welding systems and, more particularly, to systems and methods for automated cleaning of wire electrodes after welding.

BACKGROUND

One of the first steps of a welding process is establishing an electrical arc between a welding gun and a workpiece. Some arc welding systems use wire electrodes fed to the welding gun to establish the electrical arc. It is easier to establish the electrical arc with the wire electrode if the wire electrode is “clean.” However, the wire electrode has a tendency to become “unclean” (e.g., with a molten ball or other welding residue adhered to the end) during the welding process. It is more difficult to establish the electrical arc if the wire electrode is “unclean.”

BRIEF SUMMARY

The present disclosure is directed to systems and methods for automated cleaning of wire electrodes after welding, substantially as illustrated by and/or described in connection with at least one of the figures, and as set forth more completely in the claims.

These and other advantages, aspects and novel features of the present disclosure, as well as details of an illustrated example thereof, will be more fully understood from the following description and drawings.

The figures are not necessarily to scale. Where appropriate, the same or similar reference numerals are used in the figures to refer to similar or identical elements.

DETAILED DESCRIPTION

Some examples of the present disclosure relate to the automated cleaning of wire electrodes after a welding process has finished. In some examples, ensuring a welding electrode is consistently “clean” after a welding process has finished may make it easier to establish an electrical arc at the beginning of the next welding process. However, the wire electrode has a tendency to become “unclean” during the welding process.

Some attempts have been made to clean the wire electrode after the welding process has finished. For example, some operators may manually cut off the end of the wire after the welding process has finished, in order to remove any residue that may have collected there. However, this solution relies on the good memory and proactive nature of an operator. As another example, some welding systems may automatically provide a high current to the wire electrode after the welding process has finished to “spray” any remaining welding residue off the end of the wire electrode. However, spraying can produce undesirable side effects (e.g., high energy effect due to non-ideal shielding gas).

The present disclosure contemplates cleaning the wire electrode in a molten weld pool created during the welding process. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward into the weld pool immediately after the welding process has finished. The weld pool created during the welding process is likely to still be molten immediately after welding. Further, it has been observed that a molten weld pool can “clean” the wire electrode by melting and/or removing residual welding material submerged (and/or “wet”) in the weld pool. After being submerged for a sufficient amount of time, the (now cleaned) wire electrode may be retracted from the weld pool. After cleaning, the wire electrode may be more easily used to establish an electrical arc at the beginning of the next welding process.

FIGS. 1 and 2show an example perspective and block diagram view, respectively, of a welding system100. In the example ofFIG. 1, the welding system100includes a welding torch118and work clamp117coupled to a welding-type power supply108within a welding cell102. In the example ofFIG. 1, the welding torch118is coupled to the welding-type power supply108via a welding cable126, while the clamp117is coupled to the welding-type power supply108via a clamp cable115. In the example ofFIG. 1, an operator116is handling the welding torch118near a welding bench112that supports a workpiece110coupled to the work clamp117. While only one workpiece110is shown in the examples ofFIGS. 1 and 2, in some examples there may be several workpieces110. While a human operator116is shown inFIG. 1, in some examples, the operator116may be a robot and/or automated welding machine.

In the example ofFIG. 1, the welding torch118is a welding gun configured for gas metal arc welding (GMAW). In some examples, the welding torch118may comprise a gun configured for flux-cored arc welding (FCAW). In the examples ofFIGS. 1 and 2, the welding torch118includes a trigger119. In some examples, the trigger119may be activated by the operator116to trigger a welding-type operation (e.g., an arc welding process).

In the example ofFIGS. 1 and 2, the welding-type power supply108includes (and/or is coupled to) a wire feeder140. In the example ofFIG. 2, the wire feeder140houses a wire spool214that is used to provide the welding torch118with a wire electrode250(e.g., solid wire, cored wire, coated wire). In the example ofFIG. 2, the wire feeder140further includes rollers218configured to feed the wire electrode250to the torch118(e.g., from the spool214) and/or retract the wire electrode250from the torch118(e.g., back to the spool214). As shown, the wire feeder140further includes a motor219configured to turn one or more of the rollers218, so as to feed (and/or retract) the wire electrode250. In some examples, the welding system100may be a push/pull system, and the welding torch118may also include one or more rollers218and/or motors219configured to feed and/or retract the wire electrode250. While, in the example ofFIG. 2, the wire electrode250is depicted as being fed from the wire feeder140to the welding torch118in isolation, in some examples the wire electrode250may be routed through the welding cable126shown inFIG. 1with other components of the welding system100(e.g., gas, power, etc.).

In the example ofFIGS. 1 and 2, the welding-type power supply108also includes (and/or is coupled to) a gas supply142. In the example ofFIG. 2, the gas supply142is connected to the welding torch118through line212. In some examples, the gas supply142supplies a shielding gas and/or shielding gas mixtures to the welding torch118(e.g., via line212). A shielding gas, as used herein, may refer to any gas (e.g., CO2, argon) or mixture of gases that may be provided to the arc and/or weld pool in order to provide a particular local atmosphere (e.g., shield the arc, improve arc stability, limit the formation of metal oxides, improve wetting of the metal surfaces, alter the chemistry of the weld deposit, and so forth). While depicted as its own line212in the example ofFIG. 2, in some examples the line212may be incorporated into the welding cable126shown inFIG. 1.

In the example ofFIGS. 1 and 2, the welding-type power supply108also includes an operator interface144. In the example ofFIG. 1, the operator interface144comprises one or more adjustable inputs (e.g., knobs, buttons, switches, keys, etc.) and/or outputs (e.g., display screens, lights, speakers, etc.) on the welding-type power supply108. In some examples, the operator interface144may comprise a remote control and/or pendant. In some examples, the operator116may use the operator interface144to enter and/or select one or more weld parameters (e.g., voltage, current, gas type, wire feed speed, workpiece material type, filler type, etc.) and/or weld operations for the welding-type power supply108. In some examples, the weld parameters and/or weld operations may be stored in a memory224of the welding-type power supply108and/or in some external memory. The welding-type power supply108may then control (e.g., via control circuitry134) its operation according to the weld parameters and/or weld operations. In some examples (e.g., where the operator is a robot and/or automated welding machine), the operator interface144may be used to start and/or stop a welding process. In some examples, the operator interface144may further include one or more receptacles configured for connection to (and/or reception of) one or more external memory devices (e.g., floppy disks, compact discs, digital video disc, flash drive, etc.). In the example ofFIG. 2, the operator interface144is communicatively coupled to control circuitry134of the welding-type power supply108, and may communicate with the control circuitry134via this coupling.

In the example ofFIGS. 1 and 2, the welding-type power supply108is configured to receive input power (e.g., from AC mains power, an engine/generator, a solar generator, batteries, fuel cells, etc.), and convert the input power to DC (and/or AC) output power (e.g., welding-type output power). In the example ofFIG. 2, the input power is indicated by arrow202. In the example ofFIG. 1, the output power may be provided to the welding torch118via welding cable126. In the example ofFIG. 2, the output power may be provided to the welding torch118via line208. While depicted as its own line208in the example ofFIG. 2for ease of explanation, in some examples the line208may be part the welding cable126shown inFIG. 1. In the example ofFIGS. 1 and 2, the output power may be provided to the clamp117(and/or workpiece(s)110) via clamp cable115.

In the example ofFIGS. 1 and 2, the welding-type power supply108includes power conversion circuitry132configured to convert the input power to output power (e.g., welding-type output power and/or other power). In some examples, the power conversion circuitry132may include circuit elements (e.g., transformers, rectifiers, capacitors, inductors, diodes, transistors, switches, and so forth) capable of converting the input power to output power. In the example ofFIG. 2, the power conversion circuitry132includes one or more controllable circuit elements204. In some examples, the controllable circuit elements204may comprise circuitry configured to change states (e.g., fire, turn on/off, close/open, etc.) based on one or more control signals. In some examples, the state(s) of the controllable circuit elements204may impact the operation of the power conversion circuitry132, and/or impact characteristics (e.g., current/voltage magnitude, frequency, waveform, etc.) of the output power provided by the power conversion circuitry132. In some examples, the controllable circuit elements204may comprise, for example, switches, relays, transistors, etc. In examples where the controllable circuit elements204comprise transistors, the transistors may comprise any suitable transistors, such as, for example MOSFETs, JFETs, IGBTs, BJTs, etc.

In some examples, the controllable circuit elements204of the power conversion circuitry132may be controlled by (and/or receive control signals from) control circuitry134of the welding-type power supply108. In the examples ofFIG. 2, the welding-type power supply108includes control circuitry134electrically coupled to the power conversion circuitry132. In some examples, the control circuitry134operates to control the power conversion circuitry132, so as to ensure the power conversion circuitry132generates the appropriate welding-type power for carrying out the desired welding-type operation.

In the example ofFIG. 2, the control circuitry134includes a weld controller220and a converter controller222. As shown the weld controller220and converter controller222are electrically connected. In some examples, the converter controller222controls the power conversion circuitry132(e.g., via the controllable circuit elements204), while the weld controller220controls the converter controller222(e.g., via one or more control signals). In some examples, the weld controller220may control the converter controller222based on weld parameters and/or weld operations input by the operator (e.g., via the operator interface144) and/or input programmatically. For example, an operator may input one or more target weld operations and/or weld parameters through the operator interface144, and the weld controller220may control the converter controller222based on the target weld operations and/or weld parameters. The converter controller222may in turn control the power conversion circuitry132(e.g., via the controllable circuit elements204) to produce output power in line with the weld operations and/or weld parameters. In some examples, the converter controller222may only send control signals to the power conversion circuitry132if an enable signal is provided by the weld controller220(and/or if the enable signal is set to true, on, high, 1, etc.).

In the example ofFIG. 2, the weld controller220includes memory224and one or more processors226. In some examples, the one or more processors226may use data stored in the memory224to execute certain control algorithms. The data stored in the memory224may be received via the operator interface144, one or more input/output ports, a network connection, and/or be preloaded prior to assembly of the control circuitry134. In the example ofFIG. 2, the memory224further comprises a wire cleaning program300, further discussed below. In some examples, the wire cleaning program300may make use of the processors226and/or memory224. Though not depicted, in some examples the converter controller222may also include memory and/or one or more processors.

In the example ofFIG. 2, the control circuitry134is in electrical communication with one or more sensors236via line210. While shown as a separate line for ease of explanation in the example ofFIG. 2, in some examples, line210may be integrated into the weld cable126ofFIG. 1. In some examples, the control circuitry134may use the one or more sensors236to monitor the current and/or voltage of the output power and/or welding arc150. In some examples the one or more sensors236may be positioned on, within, along, and/or proximate to the wire feeder140, weld cable126, power supply108, and/or torch118. In some examples, the one or more sensors236may comprise, for example, current sensors, voltage sensors, impedance sensors, temperature sensors, acoustic sensors, trigger sensors, position sensors, angle sensors, and/or other appropriate sensors. In some examples, the control circuitry134may determine and/or control the power conversion circuitry132to produce an appropriate output power, arc length, and/or extension of wire electrode250based at least in part on feedback from the sensors236.

In the example ofFIG. 2, the control circuitry134is also in electrical communication with the wire feeder140and gas supply142. In some examples, the control circuitry134may control the wire feeder140to output wire electrode250at a target speed and/or direction. For example, the control circuitry134may control the motor219of the wire feeder140to feed the wire electrode250to (and/or retract the wire electrode250from) the torch118at a target speed. In some examples, the control circuitry134may also control one or more motors219and/or rollers218within the welding torch118to feed and/or retract the wire electrode250. In some examples, the welding-type power supply108may control the gas supply142to output a target type and/or amount gas. For example, the control circuitry134may control a valve in communication with the gas supply142to regulate the gas delivered to the welding torch118.

In some examples, a welding process may be initiated when the operator116activates the trigger119of the welding torch118(and/or otherwise activates the welding torch118). During the welding process, the welding-type power provided by the welding-type power supply108may be applied to the wire electrode250fed through the welding torch118in order to produce a welding arc150between the wire electrode250and the one or more workpieces110. The arc150may complete a circuit formed through electrical coupling of both the welding torch118and workpiece110to the welding-type power supply108. The heat of the arc150may melt portions of the wire electrode250and/or workpiece110, thereby creating a molten weld pool. Movement of the welding torch118(e.g., by the operator) may move the weld pool, creating one or more welds111.

When the welding process is finished, the operator116may release the trigger119(and/or otherwise deactivate the welding torch118). In some examples, the control circuitry134(e.g., the weld controller220) may detect that the welding process has finished. For example, the control circuitry134may detect a trigger release signal via sensor236. As another example, the control circuitry134may receive a torch deactivation command via the operator interface144(e.g., where the torch118is maneuvered by a robot and/or automated welding machine).

In some examples, welding residue may collect at an end of the wire electrode250during the welding process.FIG. 4ashows an example depiction of the welding torch118and workpiece110immediately after the welding process has finished. In the example ofFIG. 4a, the weld111has been formed by the welding process, but the final portion of the weld111has yet to cool and is still a molten weld pool404. Because the welding process has just finished, the welding torch118remains aimed at the weld pool404. As shown, a ball402of welding residue has collected at the end of the wire electrode250.

In conventional welding systems, the control circuitry134might command the wire feeder140to stop feeding the wire electrode250after detecting that the welding process has finished. However, in the welding system100of the present disclosure, the control circuitry134may instead activate the wire cleaning program300in response to detecting the welding process has finished, in order to “clean” any residual welding residue off the wire electrode250. In some examples, some or all of the wire cleaning program300may be implemented in machine readable instructions stored in memory224and/or executed by the one or more processors226. In some examples, some or all of the wire cleaning program300may be implemented in analog and/or discrete circuitry. In some examples, the wire cleaning program300may be configured to feed the wire electrode250into the molten weld pool404created by the welding process in order to “clean” any residual welding residue (e.g., ball402) off the wire electrode250.

FIG. 3is a flowchart representative of the program300. As shown, the program300begins at block302. At block302, the program300determines that the welding process has finished. In some examples, the program300may determine that the welding process has finished via detection by the control circuitry134(e.g., the weld controller220). In some examples, the control circuitry134may detect that the welding process has finished by way of a trigger release signal from sensor236. In some examples, the control circuitry134may detect that the welding process has finished via a signal sent through the connection (e.g., via weld cable126) between the welding torch118and the welding-type power supply108. For example, a signal (and/or change in voltage and/or current) may be detected by the control circuitry134, such as when the trigger119is activated and/or deactivated. In some examples, activating the trigger119may open or close a trigger circuit (not shown) in the welding torch118, while deactivating the trigger119may do the opposite. In some examples, the control circuitry134may detect that the welding process has finished via a signal detected from the operator interface144. For example, in examples where the torch118is maneuvered by a robot and/or automated welding machine, a human may terminate a welding process via the operator interface144, and the operator interface144may send a corresponding signal to the control circuitry134. In some examples, the welding process may be programmatically controlled (e.g., via instructions stored in memory224and/or executed by processor(s)226), and the termination of the welding process may be indicated to the control circuitry134(e.g., via an appropriate signal) by the program. While block302is shown as part of the program300inFIG. 3for the sake of completeness, in some examples, block302may be the impetus for executing program300, rather than being part of program300.

In some examples, an operator perceptible notification (e.g., text message, graphical depiction, audio message, sound, tone, alarm, etc.) may be outputted via the operator interface144at block302(and/or when the wire cleaning program300is executed). The operator perceptible notification may, for example, indicate to the operator116and/or other individual that the wire cleaning program300is executing, and to keep the welding torch118aimed at the weld pool404while the wire cleaning program300is executing. This may help reduce the occurrence of errors in the wire cleaning program300.

As shown, the program300proceeds to block304after block302. At block304, the program300commands an output current of IL(e.g., via one or more signals to the converter controller222), and commands a forward wire feed speed of SL(e.g., via one or more signals to the wire feeder140and/or welding torch118). In some examples, SLmay be a relatively low wire feed speed, such as, for example, 50, 75, or 100 inches per minute. In some examples, ILmay be dependent upon the type and/or size of the wire electrode250. In some examples, ILmay be a relatively low current, such as, for example, 5, 10, or 25 amps for a 0.052 inch diameter metal core wire electrode250. In some examples, ILand/or SLmay be stored in memory224and/or provided via the operator interface144. The current ILmay be set low enough to prevent another arc150and/or significant melting of the wire electrode250, but still high enough to detect a short circuit.

In the example ofFIG. 3, the program300proceeds to block306after block304. At block306, the program300checks if there has been a timeout. In some examples, the timeout check at block306may reference a threshold time entered via the operator interface144, stored in memory224, and/or otherwise provided by control circuitry134. In some examples, the timeout check at block306may further reference a clock and/or a timer of the control circuitry134. In the example ofFIG. 3, the program300ends if the threshold amount of time has passed since block304. This may prevent continuous running of the program300and/or feeding the wire electrode250, such as in situations where, for example, there is some error, or the torch118is not pointed at the weld pool402for some reason. If, however, the threshold amount of time has not passed, the program300proceeds to block308.

In the example ofFIG. 3, the program300determines if there is contact between the wire electrode250and weld pool404(and/or workpiece(s)110) at block308. In some examples, the program300may determine there is contact if a short circuit is detected (e.g., if sensor(s)236detect a current magnitude at or near ILand a zero or negligible voltage). In some examples, the program may determine there has been contact through some other means (e.g., via a camera, thermal imaging device, spectrometer, spectrophotometer, etc.). If the program300determines no contact, the program300returns to block304, as shown. If the program300determines that contact has been made, the program300proceeds to block310.

At block310, the program300commands (e.g., via one or more signals) the wire feeder140(and/or torch118) to continue feeding the wire electrode250forward into the weld pool404for a time Txand/or a distance Dx. In some examples, this continued feeding of the wire electrode250may ensure that any weld residue (e.g., ball402) at the end of the wire electrode250is sufficiently “wet” by (and/or submerged into) the weld pool404to be cleaned off. In some examples, the time Txand/or distance Dxmay be stored in memory224and/or set by an operator (e.g., via the operator interface144). In some examples, the program300may use the same wire feed speed SLset at block304, or a different wire feed speed. In some examples, the program300may instead command the wire feeder140(and/or torch118) to pause or stop feeding of the wire electrode250for time Txat block310.

FIG. 4bshows an example depiction of the welding torch118and workpiece110after the wire electrode250has been fed forward into the weld pool404. As shown, good contact is being made between the wire electrode250and the weld pool404(and workpiece(s)110, via weld pool404). In the example ofFIG. 4b, the wire electrode250has been fed forward past initial contact with the weld pool404, to the point where the ball402has been completely submerged into the weld pool404.

In the example ofFIG. 3, the program300proceeds to block312after the expiration of time Txand/or distance Dxof block310. At block312, the program300commands (e.g., via one or more signals) the wire feeder140(and/or welding torch118) to retract the wire electrode250from the weld pool404for a time Tyand/or a distance Dy. In some examples, the time Tyand/or distance Dymay be stored in memory224and/or set by an operator (e.g., via the operator interface144). In some examples, the time Tyand/or distance Dymay be the same as, greater than, or less than the time Txand/or distance Dx. In some examples, the program300may use the same wire feed speed SLset at block304, the wire feed speed set at block310, and/or a different wire feed speed.

As shown, the program300also commands (e.g., via one or more signals) the output current to a magnitude IHat block312. In some examples, the current magnitude IHmay be stored in memory224and/or set by an operator (e.g., via the operator interface144). In some examples, the current magnitude IHmay be higher than the prior magnitude ILset at block304. In some examples, the current magnitude IHmay be set at a level that keeps the wire electrode250relatively warm, to prevent the wire electrode250from cooling and becoming “frozen” (and/or stuck) to the weld pool404during retraction. In some examples, IHmay be dependent upon a type and/or size of the wire electrode250. For example, for a 0.052 inch diameter metal core wire electrode250, IHmay be 50, 75, or 100 amps.

In the example ofFIG. 3, the program300proceeds to block314after block312. At block314, the program300checks if there has been a timeout. In some examples, the timeout check at block314may reference a threshold time entered via the operator interface144, stored in memory224, and/or otherwise provided by control circuitry134. In some examples, the threshold time of block314may be the same as, greater than, or less than the threshold time of block306. In some examples, the timeout check at block314may further reference a clock and/or a timer of the control circuitry134. In the example ofFIG. 3, the program300ends if the threshold amount of time has passed since block312. This may prevent continuous running of the program300and/or retraction the wire electrode250, such as in situations where, for example, there is some error. If, however, the threshold amount of time has not passed, the program300proceeds to block316.

At block316, the program300determines whether the wire electrode250is still in contact with the weld pool404(and/or workpiece110) or if contact has ceased. In some examples, the program300may determine there is contact if a short circuit is detected (e.g., if sensor236detects the IHcurrent and an approximately zero voltage). In some examples, the program300may determine that there is no contact (and/or a cessation of contact) if an open circuit is detected (e.g., if sensor236detects no or negligible current and a substantial voltage). In some examples, the program may determine whether there is contact through some other means (e.g., via a camera, thermal imaging device, spectrometer, spectrophotometer, etc.). As shown, if contact is still detected at block316, the program300returns to block312. In some examples, if contact is still detected at block316, the program300may return to block310. If no contact is detected at block316in the example ofFIG. 3, the program300concludes that the wire electrode250has been successfully retracted out of the weld pool404and proceeds to block318.

FIG. 4cshows an example depiction of the welding torch118and workpiece110after the wire electrode250has been retracted from the weld pool404. As shown, the wire electrode250is no longer in contact with the weld pool404(and/or workpiece(s)110). In the example ofFIG. 4c, the ball402has been cleaned off the wire electrode250by the weld pool404. After this cleaning, the wire electrode250is ready to be used in the next welding process.

In the example ofFIG. 3, the program300checks whether there is an electrical arc150between the wire electrode250and the workpiece110at block318. This check may be necessary in some examples in case the current magnitude IHset at block312results in a high enough voltage to create an arc after the wire electrode250is retracted away from contact with the weld pool404(and/or workpiece110). As the welding process is supposed to be over during the program300, a new welding arc150may be undesirable. In some examples, the program300may use the sensor(s)236to determine whether there is an arc150. For example, the sensor(s)236may detect both a non-trivial current and voltage if there is an arc150. If no welding arc150is detected at block318, the program300ends. However, if a welding arc150is detected at block318, the program proceeds to block320. In some examples, the arc check at block318may be skipped, and the program300may always proceed to block320(e.g., out of an abundance of caution).

At block320, the program300commands (e.g., via one or more signals) an output current magnitude of ID. In some examples, IDmay be dependent upon a type and/or size of the wire electrode250. In some examples, the current magnitude IDmay be less than or equal to 5, 10, or 25 amps for a 0.052 inch diameter metal core wire electrode250. In some examples, the program300sets the output current magnitude to IDat block320in order to ensure that the power supply108will be outputting a known (and/or low) current magnitude when it is re-enabled at block324, rather than, for example, a higher current that may produce another arc150and/or melt the wire electrode250, which may result in another ball402forming. In some examples, the program300may skip blocks322and324, and set the output current magnitude IDto a low enough value that any arc150will extinguish itself relatively quickly.

In the example ofFIG. 3, the program300proceeds to block322after block320. At block322, the program300disables the power supply108for a time TZand/or a retraction distance DZof wire electrode250. In examples where the power supply108is disabled, the program300may command (e.g., via one or more signals) the wire feeder140(and/or welding torch118) to retract a distance DZof the wire electrode250. In some examples, the program300may disable the power supply108by setting the enable signal delivered to the converter controller222to off (and/or false, low, 0, etc.). In some examples, the converter controller222may only supply control signals to switching elements204of the power conversion circuitry132when the enable signal is set to on (and/or true, high, 1, etc.). Without the control signals, the switching elements204of the power conversion circuitry132will not operate (and/or fire), and the power conversion circuitry132will be unable to output regulated welding-type power.

In the example ofFIG. 3, the program300proceeds to block324after expiration of the time TZand/or a retraction distance DZof block322. At block324, the program re-enables the power supply108(e.g., by setting the enable signal to on). As shown, the program300proceeds to block326after block324. At block326, the program300again determines whether the wire electrode250is in contact with the weld pool404(and/or workpiece(s)110), such as through any of the methods discussed above. In some examples, the weld pool404may grow beyond its previous bounds where there has been an additional arc150, making this additional check necessary in case the weld pool404grows to such an extent that contact is once again made with the wire electrode250. If the program300detects contact, the program300returns to block312. If the program300does not detect contact, the program300ends.

The wire cleaning program300contemplated by the present disclosure allows for a still warm weld pool404to “clean” the end of a wire electrode250after a welding process has finished. This “cleaning” can facilitate easier establishment of a welding arc150at the beginning of the next welding process. Additionally, the method of “cleaning” avoids the “spraying” of prior weld stoppage cleaning programs.

As utilized herein, the terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations.

As used herein the terms “circuits” and “circuitry” refer to physical electronic components (i.e., hardware) and any software and/or firmware (“code”) which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware. As used herein, for example, a particular processor and memory may comprise a first “circuit” when executing a first one or more lines of code and may comprise a second “circuit” when executing a second one or more lines of code. As utilized herein, circuitry is “operable” and/or “configured” to perform a function whenever the circuitry comprises the necessary hardware and/or code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).

As used herein, a control circuit may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, DSPs, etc., software, hardware and/or firmware, located on one or more boards, that form part or all of a controller, and/or are used to control a welding process, and/or a device such as a power source or wire feeder.

As used herein, the term “processor” means processing devices, apparatus, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable. The term “processor” as used herein includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC), a graphic processing unit (GPU), a reduced instruction set computer (RISC) processor with an advanced RISC machine (ARM) core, etc. The processor may be coupled to, and/or integrated with a memory device.

As used, herein, the term “memory” and/or “memory device” means computer hardware or circuitry to store information for use by a processor and/or other digital device. The memory and/or memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like. Memory can include, for example, a non-transitory memory, a non-transitory processor readable medium, a non-transitory computer readable medium, non-volatile memory, dynamic RAM (DRAM), volatile memory, ferroelectric RAM (FRAM), first-in-first-out (FIFO) memory, last-in-first-out (LIFO) memory, stack memory, non-volatile RAM (NVRAM), static RAM (SRAM), a cache, a buffer, a semiconductor memory, a magnetic memory, an optical memory, a flash memory, a flash card, a compact flash card, memory cards, secure digital memory cards, a microcard, a minicard, an expansion card, a smart card, a memory stick, a multimedia card, a picture card, flash storage, a subscriber identity module (SIM) card, a hard drive (HDD), a solid state drive (SSD), etc. The memory can be configured to store code, instructions, applications, software, firmware and/or data, and may be external, internal, or both with respect to the processor130.

The term “power” is used throughout this specification for convenience, but also includes related measures such as energy, current, voltage, and enthalpy. For example, controlling “power” may involve controlling voltage, current, energy, and/or enthalpy, and/or controlling based on “power” may involve controlling based on voltage, current, energy, and/or enthalpy.

As used herein, welding-type power and/or welding-type output power refers to power suitable for welding, cladding, brazing, plasma cutting, induction heating, carbon arc cutting, and/or hot wire welding/preheating (including laser welding and laser cladding), carbon arc cutting or gouging, and/or resistive preheating.

As used herein, a welding-type power supply and/or power source refers to any device capable of, when power is applied thereto, supplying welding, cladding, brazing, plasma cutting, induction heating, laser (including laser welding, laser hybrid, and laser cladding), carbon arc cutting or gouging, and/or resistive preheating, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.

Disabling of circuitry, actuators, and/or other hardware may be done via hardware, software (including firmware), or a combination of hardware and software, and may include physical disconnection, de-energization, and/or a software control that restricts commands from being implemented to activate the circuitry, actuators, and/or other hardware. Similarly, enabling of circuitry, actuators, and/or other hardware may be done via hardware, software (including firmware), or a combination of hardware and software, using the same mechanisms used for disabling.