Patent Publication Number: US-11660698-B2

Title: Input power user interfaces for welding power supplies

Description:
BACKGROUND 
     A common metal welding technique employs the heat generated by electrical arcing to transition a work piece to a molten state, to facilitate a welding process. One technique that employs this arcing principle is wire feed welding. If the welding device is properly adjusted, the wire feed advancement and arcing cycle progresses smoothly, providing a good weld. 
     Traditionally, during a welding operation, an operator selects the level and types of resources provided to the weld location, depending, of course, on the particulars of the weld and the materials being welded. Different kinds of wire electrode, however, perform well at different operational settings of the welding device. 
     Conventionally, welding devices rely on the knowledge and acumen of the operator to select the most appropriate voltage and wire feed settings for the wire electrode being used and the particular weld conditions. Unfortunately, in many cases, the weld operator is a novice to the field, especially in the case of entry level welding devices. If the input power does not have the capacity to fully and consistently provide power demanded for a welding operation, the operator may not have information to adjust settings and/or processes, which may result in insufficient outputs to produce a good weld, or any weld at all, and may also cause issues with the welding power supply itself. 
     SUMMARY 
     Welding power supplies and user interfaces for an input power characteristics monitoring, analysis and/or presentation process 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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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: 
         FIG.  1 A  is a schematic diagram of an example welding system to implement an input power characteristics monitoring, analysis and/or presentation process, in accordance with aspects of this disclosure. 
         FIG.  1 B  is a schematic diagram of another example welding system to implement an input power characteristics monitoring, analysis and/or presentation process, in accordance with aspects of this disclosure. 
         FIG.  1 C  is a schematic diagram of another example welding system to implement an input power characteristics monitoring, analysis and/or presentation process, in accordance with aspects of this disclosure. 
         FIGS.  2 A and  2 B  is an example interface for presentation of an input power characteristics monitoring, analysis and/or presentation process, in accordance with aspects of this disclosure. 
         FIG.  3    is another example interface for the input power characteristics monitoring, analysis and/or presentation process, in accordance with aspects of this disclosure. 
         FIGS.  4 A- 4 C  provide flowcharts representative of example machine-readable instructions that may be executed by the example system of  FIGS.  1 - 3    to implement the input power characteristics monitoring, analysis and/or presentation process, in accordance with aspects of this disclosure. 
     
    
    
     The figures are not necessarily to scale. Where appropriate, similar or identical reference numbers are used to refer to similar or identical components. 
     DETAILED DESCRIPTION 
     Disclosed example power supplies, user interfaces, and methods provide for monitoring, analysis and/or presentation of input power characteristics for a welding-type power supply and/or wire feeder. 
     In some examples, a welding system includes a power supply to deliver power to a welding torch based on one or more input power characteristics (e.g., voltage, current, power, wire feed speed, gas flow rate, pulse rate, workpiece thickness, workpiece material type, electrode type, welding process, travel speed, arc length, or joint type, etc.). 
     As disclosed herein, the input power characteristics may correspond to received input power characteristics values during a welding procedure (e.g., based on material type, electrode diameter, welding process and/or tool, etc.). The input power characteristics are responsive to the power demanded during the welding operation and may change accordingly. To maintain an accounting of the input power characteristics and their values as they change during the welding operation, control circuitry may receive information regarding the input characteristics (from one or more sensors), analyze the information, and/or generate presentable indicators for display on one or more graphical interfaces (such as a meter, gauge, graphical band, value presentation, etc.). 
     Some welding power supplies can connect to and draw primary power from a variety of power sources (e.g., engine driven generators, energy storage systems, mains power, etc.). However, when a welding power supply is connected to a 120V source, the power supply may experience issues associated with the 120V service. For example, there are any number of service requirements (e.g., from the National Electric Code (NEC)) in order for a welding power supply to provide the full range of outputs. Requirements may include one or more input power characteristics, such as input voltage, input current at rated output, recommended fusing, input conductor sizing, maximum input conductor length, etc. If an extension cord is to be employed, consideration should be given to conductor size, extension cord length, etc., in order to mitigate voltage drop (which can be calculated based on a rated primary current). However, an operator may not have information of the input power characteristics and/or the power demands of the welding operation needed to make an informed decision. 
     In some examples, the welding power supply may be connected to a generator. During a welding operation, the welding power supply experiences dynamic power output requirements and the generator may not be able to meet those requirements. However, often these issues are not understood by an operator. Further, the welding conditions may change (such as during a large welding project). If the welding power supply is operated without consideration to input requirements, a number of issues may result, such as degraded weld quality, interruption of a weld, damage to the welding power supply, and/or damage to the power source. 
     For example, if the service to the welding power supply is insufficient, welding issues often occur. A common problem is that a circuit breaker in the service panel trips (disconnecting the power at the outlet). A tripped circuit breaker would provide no feedback to the user, either to the conditions that existed as the circuit breaker tripped, and/or that the circuit breaker is going to trip. Once the circuit breaker does trip, the welding power supply is no longer able to provide any information regarding the operating conditions that led to the tripped circuit breaker. 
     Yet another issue is associated with the voltage drop from conductors within an undersized service (e.g., conductors from a service panel to an outlet, conductors from an outlet to a welding power supply, etc.). Depending on the power conversion circuitry and/or type of control circuitry of the welding power supply, a number of different issues may arise. One issue is that the secondary welding voltage may sag; again, with no indication provided to the operator. Another issue is that the primary voltage may elevate, again with no indication provided to the operator. Yet another issue is that the welding transfer may change, and may change significantly enough to cause an unacceptable welding transfer, again with no indication provided to the operator. And yet another issue is that during a welding operation the welding power supply may terminate the weld altogether when the input or primary voltage is too low to continue welding. 
     The disclosed systems and methods provide advantages over conventional systems, such that an operator is provided with immediate feedback regarding characteristics of the input power (e.g., mains or primary power) with easy-to-understand graphical interfaces (e.g., meters, graphics, text, patterns, etc.). For example, the user can quickly determine if their input power levels have changed and check the power source. If an extension cord is undersized for the application the operator may either remove the extension cord or use a lower power setting on the welding power source. The user also knows how much margin they have before a circuit breaker might trip. 
     The provided graphical interface provides value ranges calculated to allow an operator to readily understand how input power variations can impact welding power supply performance and weld quality in a visual fashion. Furthermore, data corresponding to the input power variations may be stored, analyzed, and/or accessed to diagnose welding power supply issues at the job site or for later maintenance. 
     In some disclosed examples, a welding power supply includes an input circuit to receive input power from a power source, one or more graphical interfaces representing one or more input power characteristics of the input power, and a control circuitry. The control circuitry is configured to generate a graphical band representing a range of operational values including an upper limit value or a lower limit value for one or more input power characteristics based on the one or more thresholds, display the graphical band on the one or more graphical interfaces relative to a rated input value, calculate an average value of the one or more input power characteristics at the input circuit, generate a marker representing the average value of the one or more input power characteristics, and display the marker on the one or more graphical interfaces such that the position of the marker is arranged based on the average value relative to the upper limit value or the lower limit value of the range of operational values. 
     In some examples, the graphical band is a first graphical band corresponding to a first range of operational values for the one or more power characteristics based on a first input power operational threshold of the one or more input power operational threshold, the control circuitry further configured to generate a second graphical band corresponding to a second range of operational values based on a second input power operational threshold of the one or more input power characteristics. 
     In some examples, the first input power operational threshold corresponds to a first variance from the rated input value, and the second input power operational threshold corresponds to a second variance from the rated input value. In examples, the control circuitry is further configured to generate a third graphical band corresponding to a third range of operational values based on a third input power operational threshold of the one or more input power characteristics. 
     In some examples, the control circuitry is further configured to receive data corresponding to one or more input power operational threshold corresponding to the one or more input power characteristics, the one or more input power operational threshold including one or more thresholds, and calculate the range of operational values including an upper limit value or a lower limit value for the one or more input power characteristics based on the one or more thresholds. 
     In some disclosed examples, a welding power supply includes an input circuit to receive input power from a power source, one or more graphical interfaces representing one or more input power characteristics of the input power, and a control circuitry. The control circuitry is configured to receive data corresponding to first and second input power operational threshold corresponding to the one or more input power characteristics, calculate a first range of operational values including a first upper limit value or a first lower limit value for the one or more input power characteristics based on the first input power operational threshold, generate a first graphical band representing the first range of operational values for the one or more input power characteristics, calculate a second range of operational values including a second upper limit value or a second lower limit value for the one or more input power characteristics based on the second input power operational threshold, generate a second graphical band representing the second range of operational values for the one or more input power characteristics, display the first graphical band and the second graphical band on the one or more graphical interfaces relative to a rated input value, calculate an average value of the one or more input power characteristics at the input circuit, generate a marker representing the average value of the one or more input power characteristics, and display the marker on the one or more graphical interfaces such that the position of the marker is arranged based on the average value relative to the first or second upper limit value or the first or second lower limit value. 
     In some examples, the control circuitry is further configured to measure values of the one or more input power characteristics over a predetermined period of time, and calculate the average input power value based on the measured value over the predetermined period of time. In examples, the upper limit or the lower limit corresponds to a predetermined value or a percentage of the rated input value. In examples, the upper limit or the lower limit is between 5 and 50 percent of the rated input value. In examples, the one or more input power characteristics includes one or more of voltage, current, power, frequency, power factor, harmonics, distortion, or line balance. 
     In some examples, data corresponding to the one or more input power operational threshold are stored in a list of input power operational threshold, the control circuitry further configured to receive the data from the list. In examples, the one or more input power operational threshold correspond to one or more welding process types. 
     In some examples, the control circuitry is further configured to receive an input relating to a first welding process type, access a list of input power operational threshold corresponding to welding process types, and calculate the range of operational values for the one or more input power characteristics based at least in part on the welding process type. In examples, the control circuitry is further configured to control the welding power supply to maintain an output value of one or more output power characteristics within the first range of operational values or the second range of operational values. 
     In some examples, the control circuitry is further configured to calculate an extension range for the one or more input power characteristics based on one or more of the rated value, the welding process type, or the range of operational values for the one or more input power characteristics, calculate a period of time the average value can operate in the extension range, and control a power output level in response to the average value operating in the extension range for a time greater than the calculated period of time. In examples, the control circuitry is further configured to generate an alert when the average value of the one or more input power characteristics is outside the range of operational values. In examples, each graphical interface further comprises a numerical indicator corresponding to one or more of the average value or the rated value. 
     In some examples, the control circuitry is further configured to compare the average input value with the rated input value, calculate a voltage drop between the power source and the input circuit based on the comparison, and generate an alert when the voltage drop is outside a predetermined threshold value. In examples, the control circuitry is further configured to display a first characteristic on the first graphical band and a second characteristic on the second graphical band, wherein the first or second characteristic comprises one of a color, an intensity, a shape, a size, or a pattern. 
     In some examples, the control circuitry is further configured to monitor the average value over a first period of time, determine a maximum average input value over the first period of time, generate an graphical indicator corresponding to the maximum average value, and display the graphical indicator on the one or more graphical interfaces such that the position of the graphical indicator is arranged relative to the first or second upper limit value or the first or second lower limit value for a second period of time. 
     As used herein, “power conversion circuitry” and/or “power conversion circuits” refer to circuitry and/or electrical components that convert electrical power from one or more first forms (e.g., power output by a generator) to one or more second forms having any combination of voltage, current, frequency, and/or response characteristics. The power conversion circuitry may include safety circuitry, output selection circuitry, measurement and/or control circuitry, and/or any other circuits to provide appropriate features. 
     As used herein, the terms “first” and “second” may be used to enumerate different components or elements of the same type, and do not necessarily imply any particular order. 
     The term “welding-type system,” as used herein, includes any device capable of supplying power suitable for welding, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding), including inverters, converters, choppers, resonant power supplies, quasi-resonant power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith. 
     As used herein, the term “welding-type power” refers to power suitable for welding, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding). As used herein, the term “welding-type power supply” and/or “power supply” refers to any device capable of, when power is applied thereto, supplying welding, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding) power, including but not limited to inverters, converters, resonant power supplies, quasi-resonant power supplies, and the like, as well as control circuitry and other ancillary circuitry associated therewith. 
     As used herein, a “circuit,” or “circuitry,” includes any analog and/or digital components, power and/or control elements, such as a microprocessor, digital signal processor (DSP), software, and the like, discrete and/or integrated components, or portions and/or combinations thereof. 
     The terms “control circuit,” “control circuitry,” and/or “controller,” as used herein, may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, digital signal processors (DSPs), and/or other logic circuitry, and/or associated software, hardware, and/or firmware. Control circuits or control circuitry may be located on one or more circuit boards that form part or all of a controller, and are used to control a welding process, a device such as a power source or wire feeder, and/or any other type of welding-related system. 
     As used herein, the term “memory” includes volatile and non-volatile memory devices and/or other storage device. 
     As used herein, the term “torch,” “welding torch,” “welding tool” or “welding-type tool” refers to a device configured to be manipulated to perform a welding-related task, and can include a hand-held welding torch, robotic welding torch, gun, or other device used to create the welding arc. 
     As used herein, the term “welding mode,” “welding process,” “welding-type process” or “welding operation” refers to the type of process or output used, such as current-controlled (CC), voltage-controlled (CV), pulsed, gas metal arc welding (GMAW), flux-cored arc welding (FCAW), gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), spray, short circuit, and/or any other type of welding process. 
     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.  1 A  is a block diagram of an example welding system  100  having a welding-type power supply  102 , a wire feeder  104 , and a welding torch  106 . The welding system  100  powers, controls, and supplies consumables to a welding application via the power supply  102  and/or wire feeder  104 . In some examples, input power from a power source (e.g., mains power, etc.) is monitored and analyzed at the power supply  102 . Input power characteristics are determined and/or calculated by control circuitry (e.g., control circuitry  112 ), and presented on a graphical interface to provide data, information, analysis, alerts, and/or guidance to an operator. The operator may respond to conditions (including changes in conditions) to delivery of input power, as to mitigate issues stemming from insufficient input (e.g., low power input, voltage drop, inconsistent supply of power, etc.). In some examples, the analyzed data is provided to the control circuitry to automatically implement one or more actions to mitigate issues stemming from changes to the input power characteristics. 
     In some examples, the power supply  102  directly supplies input power to the welding torch  106 . The welding torch  106  may 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 supply  102  is configured to supply power to the wire feeder  104 , and the wire feeder  104  may be configured to route the input power to the welding torch  106 . In addition to supplying an input power, the wire feeder  104  may supply a filler metal to a welding torch  106  for various welding applications (e.g., GMAW welding, flux core arc welding (FCAW)). While the example system  100  of  FIG.  1 A  includes a wire feeder  104  (e.g., for GMAW or FCAW welding), the wire feeder  104  may 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 supply  102  receives primary power  108  (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 system  100 . The primary power  108  may be supplied from an offsite location (e.g., the primary power may originate from the power grid). The power supply  102  includes power conversion circuitry  110 , 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 system  100  (e.g., particular welding processes and regimes). The power conversion circuitry  110  converts input power (e.g., the primary power  108 ) 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 circuitry  110  is configured to convert the primary power  108  to both welding-type power and auxiliary power outputs. However, in other examples, the power conversion circuitry  110  is adapted to convert primary power only to a weld power output, and a separate auxiliary converter  111  is provided to convert primary power to auxiliary power. In some other examples, the power supply  102  receives a converted auxiliary power output directly from a wall outlet. Any suitable power conversion system or mechanism may be employed by the power supply  102  to generate and supply both weld and auxiliary power. 
     The power supply  102  includes a control circuitry  112  to control the operation of the power supply  102 . The power supply  102  also includes a user interface  114 . The control circuitry  112  receives input from the user interface  114 , 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 interface  114  may receive inputs using one or more input devices  115 , 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 circuitry  112  controls operating parameters based on input by the user as well as based on other current operating parameters. Specifically, the user interface  114  may include a display  116  for presenting, showing, or indicating, information to an operator. The control circuitry  112  may also include interface circuitry for communicating data to other devices in the system  100 , such as the wire feeder  104 . For example, in some situations, the power supply  102  wirelessly communicates with other welding devices within the welding system  100 . Further, in some situations, the power supply  102  communicates 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, 10 baseT, 10 base100, etc.). In the example of  FIG.  1 A , the control circuitry  112  communicates with the wire feeder  104  via the weld circuit via a communications transceiver  118 , as described below. 
     The control circuitry  112  includes at least one controller or processor  120  that controls the operations of the power supply  102 . The control circuitry  112  receives and processes multiple inputs associated with the performance and demands of the system  100 . The processor  120  may 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 processor  120  may include one or more digital signal processors (DSPs). 
     The example control circuitry  112  includes one or more storage device(s)  123  and 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 device  123  stores 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 device  124  may include a volatile memory, such as random-access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device  124  and/or the storage device(s)  123  may store a variety of information and may be used for various purposes. For example, the memory device  124  and/or the storage device(s)  123  may store processor executable instructions  125  (e.g., firmware or software) for the processor  120  to execute. In addition, one or more control regimes for various welding processes, along with associated settings and parameters, may be stored in the storage device  123  and/or memory device  124 , 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, such as to access preferred welding parameters, to store updated welding parameter settings, etc. 
     In some examples, the welding power flows from the power conversion circuitry  110  through a weld cable  126  to the wire feeder  104  and the welding torch  106 . The example weld cable  126  is attachable and detachable from weld studs at each of the power supply  102  and the wire feeder  104  (e.g., to enable ease of replacement of the weld cable  126  in case of wear or damage). Furthermore, in some examples, welding data is provided with the weld cable  126  such that welding power and weld data are provided and transmitted together over the weld cable  126 . The communications transceiver  118  is communicatively coupled to the weld cable  126  to communicate (e.g., send/receive) data over the weld cable  126 . The communications transceiver  118  may 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 transceiver  118  may implement communications over the weld cable  126 . 
     The example communications transceiver  118  includes a receiver circuit  121  and a transmitter circuit  122 . Generally, the receiver circuit  121  receives data transmitted by the wire feeder  104  via the weld cable  126  and the transmitter circuit  122  transmits data to the wire feeder  104  via the weld cable  126 . The communications transceiver  118  enables remote configuration of the power supply  102  from the location of the wire feeder  104 , and/or command and/or control of the wire feed speed output by the wire feeder  104  and/or the weld power (e.g., voltage, current) output by the power supply  102 . 
     The example wire feeder  104  also includes a communications transceiver  119 , which may be similar or identical in construction and/or function as the communications transceiver  118 . While communication over a separate communications cable is illustrated in  FIG.  1 A , other communication media, such as wireless media, power line communications, and/or any other communications media, may be used. 
     In some examples, a gas supply  128  provides shielding gases, such as argon, helium, carbon dioxide, and so forth, depending upon the welding application. The shielding gas flows to a valve  130 , 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 valve  130  may be opened, closed, or otherwise operated by the control circuitry  112  to enable, inhibit, or control gas flow (e.g., shielding gas) through the valve  130 . Shielding gas exits the valve  130  and flows through a cable  132  (which in some implementations may be packaged with the welding power output) to the wire feeder  104 , which provides the shielding gas to the welding application. In some examples, the welding system  100  does not include the gas supply  128 , the valve  130 , and/or the cable  132 . 
     In some examples, the wire feeder  104  uses the welding power to power the various components in the wire feeder  104 , such as to power a wire feeder controller  134 . As noted above, the weld cable  126  may be configured to provide or supply the welding power. The power supply  102  may also communicate with a communications transceiver  119  of the wire feeder  104  using the weld cable  126  and the communications transceiver  118  disposed within the power supply  102 . In some examples, the communications transceiver  119  is substantially similar to the communications transceiver  118  of the power supply  102 . The wire feeder controller  134  controls the operations of the wire feeder  104 . In some examples, the wire feeder  104  uses the wire feeder controller  134  to detect whether the wire feeder  104  is in communication with the power supply  102  and to detect a current welding process of the power supply  102  if the wire feeder  104  is in communication with the power supply  102 . 
     A contactor  135  (e.g., high amperage relay) is controlled by the wire feeder controller  134  and configured to enable or inhibit welding power to continue to flow to the weld cable  126  for the welding application. In some examples, the contactor  135  is an electromechanical device. However, the contactor  135  may be any other suitable device, such as a solid-state device. The wire feeder  104  includes a wire drive  136  that receives control signals from the wire feeder controller  134  to drive rollers  138  that rotate to pull wire off a spool  140  of wire. The wire is provided to the welding application through a torch cable  142  Likewise, the wire feeder  104  may provide the shielding gas from the cable  132  through the cable  142 . The electrode wire, the shield gas, and the power from the weld cable  126  are bundled together in a single torch cable  144  and/or individually provided to the welding torch  106 . In some examples, the contactor  135  is omitted and power is initiated and stopped by the power supply  102 . In some examples, one or more sensors  127  are included with or connected to in the wire feeder  102  to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to inform the controller  134  during the welding process. In some examples, one or more sensors are included in the welding power supply  102 . 
     The welding torch  106  delivers the wire, welding power, and/or shielding gas for a welding application. The welding torch  106  is used to establish a welding arc between the welding torch  106  and a workpiece  146 . A work cable  148  couples the workpiece  146  to the power supply  102  (e.g., to the power conversion circuitry  110 ) to provide a return path for the weld current (e.g., as part of the weld circuit). The example work cable  148  attachable and/or detachable from the power supply  102  for ease of replacement of the work cable  148 . The work cable  148  may be terminated with a clamp  150  (or another power connecting device), which couples the power supply  102  to the workpiece  146 . In some examples, one or more sensors  147  are included with or connected to the welding torch  106  to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to inform the controller  134  and/or  112  during the welding process. 
       FIG.  1 B  is a schematic diagram of another example welding system  152  in which the wire feeder  104  includes the user interface  114  in addition or as an alternative to the user interface on the welding power supply  102 . In the example of  FIG.  1 B , the control circuitry  134  of the wire feeder  104  implements the determinations of the welding program and welding parameters which are described with reference to the control circuitry  112  of  FIG.  1 A . 
       FIG.  1 C  is a schematic diagram of another example welding system  154  including a separate user interface  156 . The user interface  156  is a separate device, and may be connected to the welding power supply  102  and/or to the wire feeder  104  to provide commands and/or control information. The example user interface  156  includes the input devices  115  and the display  116 , and includes control circuitry  158 . The example control circuitry  158  includes the processor(s)  120  and the memory  124  storing the instructions  125 . The example user interface  156  further includes a communications transceiver  119  to enable communications between the user interface  156  and the welding power supply  102  and/or the wire feeder. 
     Although  FIGS.  1 A- 1 C  are 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. Furthermore, although power supply  102  and wire feeder  104  are illustrated as independent units, in some examples, the power supply and wire feeder can be housed in a single enclosure or otherwise integrated. Additionally or alternatively, a single controller, control circuitry, and/or interface can control operation of both the power supply and wire feeder, in some examples. 
       FIG.  2 A  illustrates example graphical interfaces  56  and  58  provided to implement the input power characteristics monitoring and/or analysis process disclosed herein. As illustrated, graphical interface  56  represents input voltage and graphical interface  58  represents input current, each corresponding to a power input (e.g. from an external source, such as mains power). Although voltage and current are used in particular examples, any power characteristic may be monitored, analyzed, and/or displayed, such as power, voltage, current, frequency, power factor, harmonic distortion, line balance, etc. 
     Information provided to the graphical interfaces  56  and  58  may be first received at control circuitry  112 ,  134 , which is configured to analyze, manipulate, store, transmit, and/or generate data for use by an operator. For example, by calculating and displaying operational ranges for the input characteristics, data corresponding to the input (e.g., variations, duration, peaks and troughs, average values, etc.) can be stored (e.g., as a historical record) and/or displayed. The data can be used to inform the operator on use of the power supply and/or to diagnose performance and/or maintenance issues. The graphical interfaces  56 ,  58 , as provided in  FIGS.  2 - 3   , display a straight-forward graphical representation of the input power characteristics, which may include diagnostic values (e.g., peak values achieved during a welding operation) and/or alerts (e.g., that a predetermined threshold and/or value has been exceeded). 
     As shown in graphical interface  56 , a first (central or middle) band  80  of the first operating range may correspond to a first “preferred” subset (e.g., variance and/or subrange) of a range of operational values (e.g., input power capacity fully delivers demanded power output), as determined by the control circuitry  112 ,  134 . 
     As shown, the first range of operational values  80  may span a first predetermined threshold (e.g., 10%) or a first predetermined value (e.g., 10V, 5A) below and/or above a rated input value  50  (e.g., an expected power characteristic value from the relevant/primary power source; 120V, 240V, 15A, 20A). The first range of operational values  80  indicates to the operator that an output from the welding power supply  100  should meet the criteria for a desired power output and/or weld performance. 
     A second band  82  (e.g., on the right and left of the first operational range) may correspond to values that are still within an acceptable second range of operational values, but are not as preferred. The range of values encompassed by the two bands  84  (e.g., on the low and high ends of the first operational range of values) represents values that, if maintained, may provide degraded weld quality and/or compromise the power supply performance. 
     The second range of operational values  82  may span a second predetermined threshold (e.g., 20%) or a predetermined value (e.g., 20V, 10 A) below and/or above a rated input value  50 . The second range of operational values  82  indicates that the welding power supply  10  output is expected to meet standard power output and/or weld performance criteria, but degraded weld performance may be expected (e.g., lower input voltages and/or current may result in a loss of higher welding outputs). 
     A third range of operational values  84  lies outside the second range of operational values  82 . For example, if an evaluation of input power characteristics (e.g., during a power-up sequence, during a welding operation, etc.) determines that one or more of the input power characteristics is less than or greater than the lower or upper values of the second range of operational values  82 , the output of the welding power supply  100  may be limited and/or disabled, and an alert will be provided to the operator (e.g., a visual, audible, haptic, or other feedback signal such as to a networked remote computer). 
     In some examples, each of the first, second and third range of operational values is displayed with one or more distinguishing characteristics. For instance, the first range of operational values  80  may be displayed as green, the second range of operational values  82  may be displayed as yellow, and the third range of operational values  84  may be displayed as red. However, other characteristics may distinguish the ranges (e.g., patterns, text, arrangement, intensity, animation, etc.). 
     An average value of the input characteristic can be calculated and displayed within the relative graphical interface, and arranged relative to the rated value and/or the one or more ranges of operational values. For example, as shown on graphical interface  56  in the example of  FIG.  2 A , the input voltage registers at 122V, and is represented in indicator  88 . A marker  86  extends into the one or more ranges of operational values  80 ,  82 ,  84 , and moves dynamically, as the average value is updated during the welding process. In some examples, as input or line voltage changes more quickly than can be observed by a person, a filter can be employed to integrate the feedback (e.g., calculating a running or periodically calculated average value). In some examples, the average value could be a percentage, but is shown with relevant units. 
     Similarly, an average current value can be calculated for graphical interface  58 . The value can be displayed in indicator  98 , and marker  96  provides a visual of the relative magnitude of the current value with respect to the range of values  90  and/or the extension range  92 . Each graphical element may be arranged on graphical interface  58  with respect to rated input current  52 . 
     In the example of  FIG.  2 A , the graphical interface  58  has two graphical bands. The first graphical band  90  shows the operational input current range. The second graphical band  92  shows an extension range, which exceeds a current value or level  94  determined as a maximum current value for the operational range (e.g., calculated based on primary input current and/or a predetermined value or threshold). The extension range  92  represents a range of current values where the input or primary current is above the preferred operation range  90 , which may lead to a circuit breaker trip, for instance. 
     In some welding processes that employ short circuit transfer (e.g., GMAW), control of the output of the welding power supply  100  may be limited to avoid exceeding operational parameters of one or more of a conversion circuit, insulation system, and/or prevent tripping a circuit breaker. For instance, the control circuitry  112 ,  134  may limit an instantaneous peak current and/or an average current (as disclosed herein) in a primary and/or a secondary circuit. During welding, the short circuit transfer often requires a high temporary peak current when a short circuit occurs. This high temporary peak current may be significantly higher than the average current operating in the operational range  90 , exceed value  94  and enter into the extension range  92 . 
     In some examples, the control circuitry  112 ,  134  may employ a “foldback” technique to limit the average output current to ensure the current demand is not maintained in the extension range  92  for long periods of time. For example, a foldback system serves as a limit on average current limit while still allowing for higher instantaneous peak currents for limited amounts of time. In the graphical interface  58 , if the welding power source is consuming too much current, the marker  96  will show in the extension range  92 . As the foldback circuit reduces the current, the marker  96  will drop below the boundary value  94  (at the interface between the operational range  90  and the extension range  92 ). 
     The display may also provide an indication that the system is limiting the current output (e.g., on the corresponding graphical interface and/or via notification interface  64 , shown in  FIG.  3   ). The indication may be visual (e.g., text, color, and/or flashing the red band on/off, switching the needle from gray to red, flashing the numerical current in the body of the needle, turning the numerical current red in the body of the needle, etc.) or audible. 
     In some examples, the welding power supply  100  may be placed on a “soft line,” in other words, the service voltage has dropped significantly as the current increases. This result can be displayed on the first graphical interface  56  as marker  86  shifts to the lower range of values. Similarly, the user interface  114  may also provide an indication that the voltage is dropping (e.g., via notification interface  64 ). 
     In some examples, at the end of each weld, one or more of the first graphical interface  56  and the second graphical interface  58  displays a hold line voltage and/or a hold line current for a predetermined period of time (e.g., 1-30 seconds). For instance, a hold line represents an average input voltage and/or current monitored over the predetermined period of time at the end of the weld. The average is calculated in order to avoid variations in the input power characteristic common at the very end of the weld (e.g., a spike or drop). Being able to view the hold line voltage and/or current represented by this hold time allows the user to complete the weld, terminate the welding operation, lift a welding helmet to view the graphical interface  56 ,  58  and observe the input voltage and/or input current during the welding operation. Following the predetermined period of time, the first graphical interface  56  and the second graphical interface  58  return to a display of the average input power characteristic value  88 ,  98 , respectively. 
     In the example of  FIG.  2 B , one or more visual indicators may be provided to illustrate one or more events associated with an input power characteristic. For example, the control circuitry may monitor the average input characteristic over a predetermined period of time in order to determine a maximum average value. For instance, during a welding operation the average voltage level may reach a maximum value (which may be calculated over a set period of time and/or for an entire weld, welding process, etc.). The maximum voltage value, represented by line  46  or other graphical indicator, may be constantly displayed (e.g., held until automatically or manually reset) to represent the highest value achieved during welding, and/or be presented historically for analysis. This graphical indicator, represented as line  46 , could also be paired with a corresponding current graphical indicator  47 , representing a current value on graphical interface  58  that shows where the other measurement was (e.g. at the same point in time) as compared to the maximum voltage level represented byline  46 . 
     In some examples, the input voltage may be at a minimum value, represented by line  45 , when the input current is at a maximum, represented by line  48 . Presenting this information graphically and/or storing this information in memory, for example, provides information for analysis which may indicate the input power is insufficient, which would be helpful for troubleshooting. In the example of  FIG.  2 B , the marker  86  has swung back to the left, yet the average value shown in  88  and the maximum value represented by line  46  remains to inform the operator (e.g., for a second period of time). 
     Similarly, line  48  is provided in graphical interface  58  to represent a maximum current value achieved during welding. Although the average value has returned to within the operational range  90 , the line  48  remains to inform the operator. The data can be maintained in a historical record as well, and can be viewed on the display  114  of the welding power supply  100 , for example. 
     Additionally or alternatively, the information may be presented in a variety of ways beyond the particular examples illustrated herein. For example, the range of operational values could be displayed as horizontal and/or vertical bars, a line graph (similar to an electrocardiogram), to list a few non-limiting examples. The values may be shown over time, as discrete periods. 
     As illustrated in  FIG.  3   , graphical interfaces  56  and  58  may be incorporated in a user interface  114  that includes additional information (e.g., welding output parameters, alerts, etc.). As shown in  FIG.  3   , graphical interface  60  represents an output voltage and graphical interface  62  represents wire feed speed, although any welding parameter may be displayed for a given welding operation. An input power indicator  57  may be displayed with one or more informational elements  59 , such as during a start-up routine, a calibration process, a transition (e.g., between welding processes), a power-down routine, as a list of non-limiting examples. 
     In some examples, messages may be displayed on an information bar  64  associated with one or more of the input power characteristics. The information can include alerts associated with changes in input power characteristic values that impact weld performance, as disclosed herein. The information bar  64  may display graphics or text to the operator to providing instructions or responses corresponding to a user input. In some examples, the information can be presented in a variety of ways to indicate the importance of the alert, such as by changes in the fonts, in display colors, and/or in association with color or graphics (e.g., red exclamation marks, etc.) such that the attention of the user may be better attracted. These features may provide supplemental guidance relating to appropriate welding settings to operators or users of the welding system(s)  100 ,  152 ,  154 , and thus ensure that welds are performed appropriately. 
     In  FIG.  3   , the user interface  114  may include a heat indicator, which represents the temperature of the system  100 ,  152 ,  154  during a welding operation. Additionally or alternatively, the heat indicator can be displayed with varying characteristics, such as changing colors to indicate a relative change in temperature (e.g., blue indicates a cold or dropping temperature, whereas red indicates a high or increased temperature). In some examples, the heat indicator can provide indications of various components and/or the environmental temperature. In examples, the displayed indicator can be selected by the operator. Such an example would be intended to convey a relative amount of heat input into the welding application. 
     With reference to  FIG.  1 A , in some examples, an additional and/or alternative electronic recording device  109  can be provided to measure and/or receive data corresponding to the input and/or output characteristics of the welding power supply  100 . For example, the electronic recording device can measure and store data during a welding operation to provide a historical record of input and/or output characteristics associated with operational values and related incidents (e.g., corresponding to a machine fault, a circuit breaker trip, a particular weld, etc.). 
     The electronic recording device  109  can be configured to measure and/or record data corresponding to input and/or output characteristics. For example, the electronic recording device  109  can be located on the primary circuit (e.g., along the input power pathway from the primary power  108  to power conversion circuitry  110 ), and may include one or more sensors and/or sensing circuitry to directly or indirectly measure the input voltage, current, power characteristics, etc. In some examples, the electronic recording device  109  may include communication circuitry to transmit and/or receive data associated with welding output from the main power source controller  112 . The data stored may reflect historical information of the power characteristics during the welding operation, such as a time period at the end of the welding operation, for example. 
     In some examples, the electronic recording device  109  can be accessed via an interface  111  while the welding power supply  100  is experiencing a fault or turned off, and can be supplied power necessary to transmit information from a connected device (e.g., a USB device, a wireless interrogator, etc.) without power being supplied to the welding power source. 
       FIGS.  4 A and  4 B  provide flowcharts representative of example machine readable instructions  200  which may be executed by the example welding system  100  of  FIG.  1 A , the example welding system  152  of  FIG.  1 B , and/or the example welding system  154  of  FIG.  1 C , to configure one or more graphical interfaces representing input power characteristics (e.g., for one or more welding processes). The example instructions  200  may be stored in the storage device(s)  123  and/or the memory  124  and executed by the processor(s)  120  of the control circuitry  112 . The example instructions  200  are described below with reference to the example graphical user interfaces of  FIGS.  1  through  3   . 
     In block  202 , an input power is received at a welding power supply from a power source (e.g., from mains power). In block  204 , the input power is monitored and/or analyzed by control circuitry (e.g., control circuitry  112 ,  134 ,  120 ), to determine one or more input power characteristics (e.g., values associated with power, voltage, current, frequency, power factor, harmonics, distortion, line balance, etc.). 
     In block  206 , data corresponding to one or more input power operational thresholds corresponding to the one or more input power characteristics is received at the control circuitry. In some examples, the one or more input power operational thresholds correspond to one or more welding process types. Thus, the data from an input relating to a first welding process type is received at the control circuitry (from an operator, a weld plan, based on a recognition of a particular welding type tool, etc.). In some examples, the control circuitry may access a list of input power operational threshold corresponding to welding process types (e.g., at storage device(s)  123  and/or the memory  124 , on a networked system, etc.). A range of operational values for the one or more input power characteristics can then be calculated based at least in part on the welding process type. 
     In block  208 , a first range of operational values including a first upper limit value or a first lower limit value for the one or more input power characteristics is calculated by the control circuitry based on the first input power operational threshold. In some examples, the data is stored in a list of values corresponding to the one or more input power characteristics, accessible to the control circuitry (e.g., at storage device(s)  123  and/or the memory  124 , on a networked system, etc.). In some examples, the upper limit or the lower limit is a predetermined value or a percentage (between 5 and 50 percent) of the rated input value. 
     In block  210 , a first graphical band representing the first range of operational values for the one or more input power characteristics is generated by the control circuitry. 
     In block  212 , a second range of operational values including a second upper limit value or a second lower limit value for the one or more input power characteristics is calculated by the control circuitry based on the second input power operational threshold. 
     In block  214 , a second graphical band representing the second range of operational values for the one or more input power characteristics is generated by the control circuitry. 
     In block  216 , the first graphical band and the second graphical band are displayed on one or more graphical interfaces (e.g., graphical interfaces  56 ,  58 , on display  48 , etc.) relative to a rated input value (e.g., values  100 ,  102 ). 
     In block  218 , an average value of the one or more input power characteristics at the input circuit is calculated. In some examples, the values of the one or more input power characteristics are measured over a predetermined period of time, and the average input power value is calculated based on the measured value over the predetermined period of time. 
     In block  220 , a marker representing the average value of the one or more input power characteristics is generated. In block  222 , the marker is displayed (e.g., on display  48 ) on the one or more graphical interfaces such that the position of the marker is arranged based on the average value relative to the first or second upper limit value or the first or second lower limit value. 
     In some additional or alternative examples, as provided in  FIG.  4 B , a method  230  can be executed such that the control circuitry controls a welding power supply output based on the first and second ranges of operational values. As shown in block  232 , the control circuitry is further configured to compare an output value corresponding to one or more output power characteristics to the first range of operational values or the second range of operational values. 
     In block  234 , the control circuitry determines if the output value is outside of the first range or the second range. In block  236 , the control circuitry controls the welding power supply to maintain the output value within the first range of operational values or the second range of operational values, based on the comparison. 
     In some additional or alternative examples, as provided in  FIG.  4 C , a method  240  can be executed such that the control circuitry controls a welding power supply output based on an extension range (e.g. extension range  92 ). For example, an extension range beyond a first operational range may be calculated such that the corresponding welding output may operate in the extension range for a limited amount of time. In particular, the control circuitry is further configured to calculate an extension range for the one or more input power characteristics based on one or more of the rated value, the welding process type, or the range of operational values for the one or more input power characteristics as shown in block  242 . 
     In block  244 , the control circuitry calculates a period of time the average value can operate in the extension range. For example, at greater values (e.g., higher current values), the amount of time the output value can maintain that value level is less than at lower values (e.g., near the border of the operational range). 
     In block  246 , the control circuitry compares the output value to the values in the extension range. In block  248 , the control circuitry determines whether the output value can remain in the extension range and for how long. 
     In block  250 , the control circuitry controls a power output level in response to the average value operating in the extension range based on the determination. For example, if the output value is operating within the extension range for a time greater than the calculated period of time, the output value will be lowered. As the value lowers, the time period may be calculated dynamically to update the amount of time and/or rate of lowering the value. Further, one or more sensors may be employed to determine the amount of time the input value may be maintained within the extension range and for how long (e.g., a temperature sensor). 
     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. 
     While the present method and/or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present method and/or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, block and/or components of disclosed examples may be combined, divided, re-arranged, and/or otherwise modified. Therefore, the present method and/or system are not limited to the particular implementations disclosed. Instead, the present method and/or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents.