Patent Publication Number: US-2015088285-A1

Title: Configurable welding interface for automated welding applications

Description:
FIELD OF THE INVENTION 
     The present invention is directed to a method and apparatus for configuring welding operations. 
     BACKGROUND OF THE INVENTION 
     As the level of automation has increased in mass production facilities, and the speed of welding operations has increased, it has become increasingly important for management personnel to monitor and control welding parameters, processes, and weld cell set-up parameters in a facility. Proper monitoring and control helps to ensure consistent and proper joining of materials, to ensure that completed welds fall within predetermined quality parameters, and to ensure that material waste and operational downtime is avoided. 
     The need for improved monitoring, moreover, has increased in recent years as welding personnel on the factory floor are frequently inexperienced in welding operations. Often, operators are minimally trained, and cannot properly choose weld parameters, or identify and correct for problems encountered during welding processes and weld set-up. Therefore, it is also important for management personnel to monitor weld and operator performance, and to quickly identify problem operators and areas. 
     As a result, there are differing levels of monitoring requirements in most facilities. Operators are typically interested only in monitoring very basic command and readout parameters, and in having access to very basic controls. Supervisory personnel, however, need to access large numbers of control parameters, feedback parameters, and weld set-up parameters to properly monitor, control, and troubleshoot welding problems. Moreover, it is important for supervisory personnel to be able to choose the types of data monitored, in order to evaluate and focus in on parameters that might be outside of an appropriate range, or that might provide a basis for analyzing problems in a weld. Monitoring selected controls and parameters simplifies the process for management personnel to analyze the welding process, identify problems, and make corrections before significant down time or waste of material occurs. 
     Additionally, when problems are encountered with equipment in a weld cell, or with consumables in the cell, it is important for management personnel to identify these failures and to make correction and replacements easily. In an automated environment, it is particularly important to be able to replace a piece of equipment from a cell with an alternative component providing the same feature, and to troubleshoot the removed piece of equipment offline. In these situations, it is important to minimize the amount of time required to set up the system for the alternative component, and to provide a “plug and play” solution to limit downtime. The present invention addresses these issues. 
     SUMMARY OF THE INVENTION 
     In one aspect of the invention, a welding power source is provided. The power source includes a power supply, a controller coupled to the power supply to provide weld parameter control signals to the power supply, and an embedded web server in communication with the controller and a remote client browser. The web server is programmed to allow a user accessing the remote client browser to select between a plurality of functions for displaying and controlling weld parameters of the welding power supply, to provide a customized operator interface at the remote client browser for monitoring and controlling the power supply. The user, therefore, can selectively control and display weld parameters at the remote client browser. 
     In another aspect of the invention, a method for providing a customizable remote interface for a welding power source and associated wire feed system having an embedded web server is provided. In this method, an embedded web server is communicatively coupled to a controller of the welding power source. The server is programmed to provide selective access to weld functions that provide at least one of a display, a control, and a command function of the welding system from a remote browser. Access to the embedded server is provided from the remote web browser, wherein an operator at the remote web browser can selectively choose among the weld functions to customize an interface to display, control and command weld functions from the remote browser. The customized remote interface can then be stored for recall. 
     These and other aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a block diagram of a welding system capable of use in the present invention; 
         FIG. 2  is a simplified block diagram of the embedded web server in the welding system of  FIG. 1 , illustrating data storage and flow between an embedded web browser and a remote web browser; 
         FIG. 3  is screen shot illustrating a web interface login screen for accessing the welding system of  FIG. 1  from a remote browser; 
         FIG. 4  is a screen shot illustrating a top level menu for accessing a remote operator interface and remote operator interface configuration, along with other functions, for use in the welding system of  FIG. 1 ; 
         FIG. 5  is a screen shot illustrating a first screen for selecting a remote operator interface; 
         FIG. 6  is a screen shot illustrating a remote panel view as seen from a remote web browser; 
         FIG. 7  is a screen shot illustrating a first selection screen for establishing a customized remote interface; 
         FIG. 8  is a screen shot illustrating the steps for establishing a custom interface; 
         FIG. 9  is a second screen shot illustrating the steps for establishing a custom interface; 
         FIG. 10  is a screen shot illustrating the customization process just prior to completion; and 
         FIG. 11  is a screen shot illustrating a customized interface after completion. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the Figures and more particularly to  FIG. 1 , an exemplary welding system  10  for automatic and semi-automatic welding is shown. The welding system  10  includes a housing  11  containing a power supply  12 , a controller  16 , and a communications system  30  for communicating with external components. These external components can be, for example, the components of a welding cell, including flexible or hard automation components, such as a welding robot  21 , a programmable logic controller (PLC)  27 , and fixtures  29 . Alternatively, or additionally, the external components can include one or more computer or computer network  31 , provided in a factory automation system. The communications system  30  can be connected to a series of networked welding systems  10 , either directly or through one or more computer  31 . Bi-directional communications between the welding system  10  and external devices are preferably provided through an embedded web server  33  in communications system  30 . 
     Referring now also to  FIG. 2 , a simplified block diagram of data storage and communication between the embedded web server  33  and remote client web browsers  37  provided on external devices such as those described above is shown. The screens associated with web server  33  are implemented through a combination of static files  43  stored in memory on the weld system  10 , and dynamically generated files  41  created by web server extensions  45  running on the web server  33 . The static files  43  include HTML web pages, cascading style sheet documents, image files and JavaScript source code documents. These files provide non-dynamic content for the web interface and a framework for dynamic content. Dynamic, variable data is provided via server extensions  45  executed on the embedded microprocessor in the welder, and is stored in the dynamically generated files  41 . This data can include, for example, a weld parameter library of variable data related to the control and performance of weld system  10 . The variable data in the weld parameter library can include both input commands and output data, such as, for example, weld command parameters for controlling the power supply  12  and wire feed system  20 ; digital control commands for activating and deactivating weld system components; digital feedback or state data indicating the state of weld system components; and weld parameter feedback data, indicating the operational state of weld parameters. An exemplary table illustrating the type of variable data that can be stored in a weld parameter library is provided in Table 1 below: 
     
       
         
           
               
               
             
               
                   
                 TABLE 1 
               
               
                   
                   
               
             
            
               
                   
                 Weld Command Parameters/Command Functions 
               
               
                   
                 Volts 
               
               
                   
                 Wire Feed Speed 
               
               
                   
                 Frequency 
               
               
                   
                 Pulse width 
               
               
                   
                 Rise time 
               
               
                   
                 Fall time 
               
               
                   
                 Torch Travel Speed 
               
               
                   
                 Torch Angle 
               
               
                   
                 Weld Component Control 
               
               
                   
                 Commands/Control Functions 
               
               
                   
                 Gas 
               
               
                   
                 Wire Feed Forward 
               
               
                   
                 Wire Feed Reverse 
               
               
                   
                 Contactor 
               
               
                   
                 Program select 
               
               
                   
                 Weld Component State 
               
               
                   
                 Parameters/Diagnostic Parameters 
               
               
                   
                 Gas On 
               
               
                   
                 Wire Feed Forward 
               
               
                   
                 Wire Feed Reverse 
               
               
                   
                 Wire Stick Detect 
               
               
                   
                 Touch sense Detect 
               
               
                   
                 Volt Sense Detect 
               
               
                   
                 Current Detect 
               
               
                   
                 Contactor On 
               
               
                   
                 Coolant On 
               
               
                   
                 Weld Feedback Parameters/Display Parameters 
               
               
                   
                 Voltage Feedback 
               
               
                   
                 Current Feedback 
               
               
                   
                 Wire Feed Speed 
               
               
                   
                 Gas Pressure 
               
               
                   
                 Coolant Pressure 
               
               
                   
                 Torch Travel Speed 
               
               
                   
                 Torch Angle 
               
               
                   
                   
               
            
           
         
       
     
     Variable data, such as the data stored in the weld parameter library, can be combined with the static data  43 , which can include pre-configured HTML pages, via JavaScript executed on the remote web browser  37 . Alternatively, the variable data can be accessed from a remote client web browser  37  at a web-enabled remote robot  21 , PLC  27 , networked welder  10 , computer  31  or other device. The variable data provided in the weld parameters library can then be retrieved through an HTML script or other program running at the web-enabled remote device  37 , and, as established by the HTML script, selective weld feedback and weld component state parameters can be viewed remotely. Additionally, the HTML script can selectively provide control of the weld control command parameters and weld component controls from the remote device  37 . 
     High speed data exchange, as for, example, for communications with remote devices  37 , is carried out through Javascript XHTTP requests, and the appropriate server extensions respond to the requests by returning requested data in JSON or XML format. Requests to the server  33  and all response from the server  33  are given an ordering number so that under high data loss conditions on the most recent data is used. 
     As discussed above, data can be retrieved from welding system  10  either by viewing web pages with variable data from the server extensions included or by downloading generated log or configuration files directly. Data is transmitted to the welding system  10  either via HTTP queries or by uploading files. Although a web server  33  is described here, in addition to or as an alternative to a web server  33 , the communications system  30  can include a serial communications link such as DeviceNet, Profibus, RS-232 or other communications systems, or through a network communications device such as an Ethernet connection, or other wired or wireless communication devices. 
     Referring again to  FIG. 1 , the controller  16  can include one or more microcontroller, microprocessor, digital signal processor, or other programmable controller, along with an internal or external memory component  18 , capable of storing weld configuration data, welding programs and procedures specified by the user. The controller  16  may also be connected to a user interface  32 , which can be mounted in the housing  11 , or provided external to the housing  11  and welding system  10 , and can include a user display and input devices, such as keys, switches, joysticks, analog or digital potentiometers, or other devices to provide information to and receive information from an operator or user of the welding system  10 . 
     Referring still to  FIG. 1 , the welding system  10  can also include an input/output board (I/O board)  17 , which provides connection points for external equipment to both provide input signals to the welding system  10  and to receive discrete outputs from the welding system  10 . The inputs and outputs can include, among other indicators, welding process state conditions and error conditions. Common welding process state condition signals input and output through the I/O board  17  can include, for example, contactor on (weld on), gas valve on (purge), wire feed motor foreword (jog), wire feed motor reverse (retract), weld program selection, and touch sense detect. Common error conditions can include, for example, voltage sense error, arc start error, wire stick errors, motor over current errors, coolant flow errors, or gas flow errors. Analog input and output signals, including voltage command and feedback, wire feed command and feedback, and current feedback can also be provided on the I/O board  17 . Welding state data, error data, feedback and command data can also be transmitted to and from the welding system  10  through communications system  30  discussed above, and by access to a weld parameter library as described above. 
     Referring still to  FIG. 1 , the welding system  10  is connected to an input power supply line  15 , typically a three phase supply, which provides power both for the control circuitry and for the power supply  12 . Voltage and current sensors (not shown) can be provided on the input power supply line to allow the power to power supply to be monitored, typically by controller  16 . The welding power supply  12  is preferably an inverter power system, and can be a constant voltage power supply or a constant voltage/constant current power supply, and preferably includes pulsing capabilities, providing the ability to perform MIG(GMAW) welding, pulsed MIG (GMAW P) and flux-cored (FCAW) welding. 
     Referring still to  FIG. 1 , the controller  16  of welding system  10  is further connected to external welding components including a wire feed system  20 , a gas valve  23 , and, optionally, a coolant system  25 . The wire feed system  20  includes a motor  19  that drives wire through drive rolls and a liner to a torch or gun  13  including a contact tip. The gas valve  23  can be either an on/off valve, a metered valve controlled by controller  16 , or can include a separate or integral flow meter. Similarly, when a coolant system is provided, the system can include an on/off or metered valve, and flow metering devices. 
     Optionally, the welding system  10  can also be connected to external input and output signals provided, for example, by components in a welding cell. The fixtures  29 , for example, can include devices such as clamps for maintaining a work piece  14  in position during a weld, and preferably also include sensing devices, such as devices for providing a signal to the controller  16  when associated clamps either open or close, and proximity sensors for sensing a position of the work piece  14  in the fixture  29  or a position of a welding torch approaching the work piece  14 . Additionally, a series of light emitting diodes, laser diodes, or other lighting elements can be provided in the fixture either to illuminate an area to be welded for the operator, or to provide an indicator to the operator. The indicator can, for example, indicate which in a series of welds is to be performed, providing a sequence for the operator. Lighting and other visual aids can also be used to indicate when a welded part is complete. Audio-producing devices, such as buzzers and horns, can also be associated with the fixture to provide a signal to an operator or supervisor when a weld is complete, when an error has occurred, or in various other situations. These devices can be connected directly through the communications system  30 , or through an external device such as the PLC  27 , robot  21 , a remote computer system, or other controller. 
     The welding system  10  can be used in various modes of operation, including both semi-automatic and automatic welding. Weld command parameters can be stored as pre-programmed weld procedures in memory  18  or provided to the weld system  10  through communications system  30 , or selected through inputs to the I/O board  17 . External devices, such as a handheld gun or torch or other device with a trigger switch, a robot controller associated with robot  21 , PLC  27 , or a remote system and display such as a externally connected PC, can provide a signal to the controller of the welding system  10  to start the weld. The weld parameter commands can be retrieved from memory  18 , or be provided from the robot  21 , PLC  27 , or other external device through communications system  30 . 
     In operation, the controller  16  receives a trigger signal as described above and commands the power supply  12  to provide welding current and voltage to start an arc at the work piece  14 . Command levels for controlling the weld can be set and stored internally in memory  18 , or can be received from the external components, such as robot  21  and PLC  27 , or other controllers or computers as discussed above, either in the form of analog or digital control signals. Based on the input commands, the controller  16  also commands the wire feed system  20  to drive filler metal from the motor  19  to a contact tip in torch  13 , providing wire to the weld at the work piece  14 . The controller  16  also controls the gas valve  23  to selectively provide shielding gas to the weld. Depending on the type of gas valve used, the controller  16  can provide a simple on/off signal, or control the level of flow from the valve  23 . 
     During operation, the controller  16  receives feedback from a voltage sensor  26 , a current sensor  28 , and a wire feed speed sensor or tachometer  24 , and can also optionally monitor gas flow through a gas flow sensor associated with the gas valve  23 , and coolant flow in coolant system  25 . The feedback data is used by the controller  16  to control the power supply  12 , wire feed system  20 , and gas valve  23 . Additional feedback data can also be provided from external components. This data can include, for example, travel speed of the torch, proximity sensor input data, clamp closure data, and other data. The controller  16  can also monitor input voltage and current levels from input power lines, and provide feedback data relate to these values, as well as average motor voltage and current values. 
     Referring again to  FIG. 2  and now to  FIG. 3 , as described above, the welding system  10  can include a remote operator interface server extension  45  which allows weld parameter controls and commands for welding system  10  to be provided from a web browser  37  at a web-enabled remote device such as a robot  21 , PLC  27 , a network of welding systems  10 , or remote computer system or server  31 , and enables both control and monitoring function from a remote location. This remote operator interface, moreover, can be customized to provide access to the control, command, diagnostic, and display data selected by a user, and therefore to customize the display either for a specific function, or for a specific user. 
     To access the remote control interface from a remote device, the user activates the web browser  37  at the remote interface and accesses a web interface login screen  40 , constructed using data from the static files  43  and dynamically generated source files  41  described with reference to  FIG. 2 , above, from the embedded web server  33 . The interface login screen  40  prompts the user to select a user profile from a drop down menu  42 . As shown here, the access levels include an operator access level, weld engineer access level, and a weld supervisor access level. 
     After the user profile is selected through the drop down box  42 , the user activates icon  44  to log in to the system, and is prompted to provide identification (not shown). The identification can be a user name and password, or an electronic or mechanical key, such as an RFID token, or biometric authentication. For purposes of this description, the user is assumed to have chosen the “weld engineer” user profile and to have logged into the system. When logged in as either an operator or weld supervisor, however, the user would be provided with fewer or different options for configuring the system than as described below. 
     Referring now to  FIG. 4 , after the password or other identification is accepted, the user accesses a main interface menu  50 . From the main interface menu  50 , the user can select between a number of different links, including a remote operator interface control link  52 , a monitoring link, a configuration link, a maintenance and update link, and a diagnostic link. 
     Referring now to  FIG. 5 , when the remote operator interface control link  52  is selected, a display screen  53  is provided allowing the user to select between a panel view  54  and a custom control interface  55 . Referring now to  FIG. 6 , the panel view  54  provides a virtual panel display which is configured in the same manner as a display provided, for example, on a user interface  32  associated with the welding system  10 . Here, fairly simple control and display options are provided. The user can select a weld program, select a process, wire type, and gas type, and can view and adjust voltage, arc adjust, wire speed, and amps. 
     Referring again to  FIG. 5 , when the user instead selects the custom control interface link  55 , the user is provided with the option to customize a weld interface that can be operated from a web browser  37  and that provides access to a selected number and type of functions. By way of example here, the functions available for configuration on the remote display are categorized as display, control, diagnostic, and command functions. The “display functions” allow the user to monitor and display current welding conditions by displaying welding parameter values such as, for example, an actual voltage, current, and wire feed speed during a weld, as well as a selected weld process or weld program. The user can also opt to display the command values provided to the welding system  10 , including a voltage/trim command, a wire feed speed command, and an arc adjustment or inductance command. “Command functions” allow a user to establish a command value from a welding process from a range of available values for controlling the power supply  12  and wire feed system  20  of the welding system  10  from the remote interface, and again, specifically allow adjustment of a voltage/trim command, a wire speed command, and an arc adjustment or inductance command. The “command functions” can also allow for selection of a weld program or a weld process from the interface from among a number of available options. The “control functions” provide on/off controls at the welding system  10  from the remote interface and can include, for example, a trigger or start/stop weld function, and purge, jog, and retract controls, which selectively activate the gas valve  23  and motor  19  in a forward or reverse direction. 
     “Diagnostic functions” allow the user to monitor parameters that can be indicative of weld or welding equipment malfunction as, for example, a current and voltage produced by the motor  19 , and the level of the input power line connected to the welding system  10 . Diagnostic data displayed at the remote interface can also include error data, such as a voltage sense error, an arc start error, wire stick errors, motor over current errors, coolant flow errors, or gas flow errors, and weld state data, such as contactor, jog, retract, remote program selection, standby and E-stop states. These errors are determined by the controller  16  in a manner known to those in the art. 
     Although specific functions are shown and described here, it will be apparent that these functions are by way of example only, and that a user-configured interface could include any number of display, control, command, diagnostic, and other functions. For example, from a remote interface, a user could also adjust timed parameters, such as pre-flow, post-flow, arc start delay, and burn back. Additionally, functions useful in setting up replacement equipment in a cell, such as a “robot type” and a “dry run” selection could also be configured on a remote user interface to enable activation of these functions. “Other” functions, such as an option of enabling a camera to visually monitor a weld in progress, can also be provided. 
     Referring now to  FIG. 7 , from the custom control interface screen  56 , the user initially selects a number of functions to be displayed on the customized interface by activating up/down operational controls  60  and  62 . When satisfied with the selected number, the user selects a “continue” icon  64 . By way of example here, twenty-five functions are available. However, it will be apparent that any number of functions could be provided, and that the number of functions can be varied based on the size of the display at the remote interface, the access level of the user, and many other variables. The access level, for example, can be used to increase or decrease the number of functions available to a user. Thus, for example, an operator might be provided with six available options, a supervisor with fifteen, and a weld engineer with twenty-five. 
     When the save icon  64  is selected from screen  56 , an interface configuration screen  68  is displayed, as shown in  FIG. 8 . Here, an interface box  80 ,  82 ,  84 ,  86 ,  88 , and  90 , is provided on screen  68  for each of the 6 functions selected above, and the user is presented with a drop down menu allowing the user to select between the different categories of functions described above. Specifically the user is prompted to associate each interface box on the remote screen with a selected display  70 , control  76 , diagnostic  74 , or command  72  function category. An “other” category,  72 , or other functions, such as timing and set-up functions, can also be provided as described above. The functionality of the interface box will vary depending on the selected category. Thus, for example, a command function will provide both a data display and a user interface that will allow a user to input a selected command value, while a display interface box provides only the ability to display a value, and a control interface only an an/off activation user interface control. 
     Referring now to  FIG. 9 , after a category is selected for an interface box, the user is presented with another drop down menu, allowing the user to identify a specific function for the interface box within the selected function category. As shown here, in the display category  70 , the user can elect to display an actual voltage, an actual current, an actual wire speed, an actual weld program or a weld process in the selected box. The user can also elect to monitor a command value, such as a voltage/trim command, wire feed command, and arc adjust/inductance command. In the command category  72 , the user is prompted to select between voltage/trim, wire speed, arc adjust, inductance, or a weld process or weld program, as described above, and can adjust the selected values from the remote interface. Here, user inputs would be associated with the interface box to allow a user to adjust a value, or select between a list of functions. As described above, these inputs could be hardware inputs associated with an existing keyboard or keys, joysticks, etc., or provided as touch screen or mouse-driven icons. Various methods of providing inputs will be apparent to those of skill in the art. In alternate embodiments of the invention, the user could also select an input device to associate with selected input boxes from, for example, a menu. 
     Referring now to  FIG. 10  when the diagnostic category  74  is selected, the user can select to display a motor voltage or a motor current, and to monitor a line power in the facility in which the welding system  10  is operating. The motor parameters can be monitored, for example, to identify and diagnose problems in the wire feed system. Input line power, similarly, can be monitored to determine both the input level of the power, and fluctuations that might cause problems in the output of the power system  12 . As described above, the diagnostic category  76  can also allow a user to display welding state data (contractor, jog, restart, pause) and error data (wire stick, arc start error, etc.) 
     Referring still to  FIG. 10 , in the control category  76 , the user can select a jog, wire retract, purge control, and a program start/stop control. As each of these functions require a user to provide an input, for the control category  76  the interface boxes are associated with an input device which can be, for example, an icon on a touch screen, a key dedicated from a keyboard, a mouse activated icon, or various other input devices, as will be apparent to those of skill in the art. 
     After each of the selected boxes is associated with a specific function, the user selectively activates the build icon  83 . When the build icon  83  is activated, the screen configuration data is saved in a JavaScript which can be stored either as a URL for the page, in a cookie stored on the client browser  37 , or in a database stored in memory  18  associated with the web browser  33  in the welding system  10 . Alternatively, if additional functions are desired, the user can select the change number icon  85  to add additional functions to the display. 
     Referring now to  FIG. 11 , after the “build” function is completed, the selected command, diagnostic, control and other functions are all provided on the screen  86 . In the example shown here, the user can view the actual voltage and current program, monitor the current program and error status, and select a program. 
     The present invention therefore provides a significant advantage over the prior art by providing a highly flexible display system. By selecting the types of data to be displayed on the screen and the available controls, specific functions can be customized, and various levels of control can be provided. Thus, for example, customized displays could be provided for operators at varying training levels. For an inexperienced operator, for example, the controls could be limited to a weld program selection and a start/stop control, and all other controls could be disallowed. For a more sophisticated operator or a supervisor, the display could provide access to control a voltage and wire feed command level, and provide monitoring functions including actual voltage and wire feed speeds. 
     A remote display screen could also be customized to allow a supervisor or other personnel to monitor a weld from a remote location. Here, for example, display parameters such as voltage and wire feed speed feedback could be monitored, in conjunction with error data. Additionally, to troubleshoot problems with the welding equipment, a user could establish customized screens providing specific sets of display and control functions. Thus, for example, to troubleshoot a wire feed problem, a user could elect to control a jog and a retract function, to monitor wire feed speed command, actual wire feed speed feedback, motor voltage and current, and monitor a wire feed relay. 
     Additionally, screens could be customized to simplify equipment replacement. Here, for example, a screen could be provided with a robot type selection, a dry run control, and purge, jog and retract switches. These controls would allow a user to associate the connected welding system  10  with an appropriate robot  21 , and to verify operation of the gas valve  23  and motor  19  when setting up a weld cell. As these various remote operator interfaces are constructed, they can be bookmarked or saved as a favorite, and then recalled when needed. 
     Although, as described above, in one aspect of the invention, the user accesses pre-configured web screens  40 ,  50 ,  53   54 ,  55 , and  68  from a remote web browser  37  to provide a pre-configured display, a user can also configure remote control and command screens at remote web browsers  37  through customized html scripts or other programs running on the remote web browser. These programs can, for example, access the functions provided in a weld parameter library, discussed above with reference to  FIG. 2 , and provide controls for commanding the power supply  12 , wire feed system  20 , gas valve  23 , coolant  25 , or externally connected devices such as the robot  21 , PLC  27 , or other hard automation components. In addition, through access to the weld parameter library, html scripts at the web browser  37  can access weld feedback and weld state parameter data and display this data. Alternatively, a user could monitor the data, or combine feedback and state parameters, to establish self-configured error conditions or alarm conditions. As discussed above, through access to available weld control and feedback parameters, the user can configure specific screens and provide specific access for various levels of users. 
     Referring again to  FIG. 4 , when using the pre-configured screens provided through web server  33 , various other functions are available to the weld engineer from the main menu  50 , as discussed above, including a monitoring link, configuration link, and a diagnostic link. When the monitoring link is selected, the user can, for example, view weld data and summaries, access monitoring logs, and download weld wave form data. 
     From the configuration link, the user can edit welder configuration data and save this data to a PC or upload the data from a PC. Configuration data accessed from this screen can include, for example, provide access to activate or deactivate a number of different errors including a voltage sense error, an arc start error, arc run time errors, wire stick errors, motor over current errors, coolant flow errors, or gas flow errors. Additionally, the configuration screen can provide locks to allow a supervisor to either selectively or globally lock access to weld programs or functions. 
     The maintenance link can provide a system back up and recovery options, and software update options. In the diagnostic screen the user can view and clear an error log, view the states of various inputs and outputs including, for example, the contactor, jog, retract, remote program selection, e-stop, wire feed and voltage outputs including current detect, standby, error modes, wire stuck errors, coolant errors, touch sense errors, voltage feedback and current feedback can be viewed. From this screen the user can also control the contactor, the gas valve, and the motor in both the forward and reverse direction in order to verify the operation of the contactor and any purge functions and jog functions. From the diagnostic screen, the user can also download current status and debugging information, and email the data to a service center for assistance with troubleshooting. 
     It should be understood that the methods and apparatuses described above are only exemplary and do not limit the scope of the invention, and that various modifications could be made by those skilled in the art that would fall under the scope of the invention. For example, while functions are provided in various category types above, and the selection process is described as including a category selection and a function selection. it will be apparent that all available functions could be displayed to a user at one time, and the user could select between the displayed functions rather than selecting by function category as described above. Alternatively, a function look-up display could be provided, or the various functions could be provided on a menu. 
     Furthermore, while a specific set of screens is described above, it will be apparent that these screens are provided by way of example only, and that the described functions could be implemented in a number of different ways, and in various configurations. Additionally, although specific data types are described with reference to each of the screens described above, it will be apparent that the data could be configured in any number of ways. 
     Furthermore, although the embedded web server is shown above as provided internal to a housing of the welding power supply, it will be apparent that the server could be provided in an external housing, or provided in a housing elsewhere within the welding system. 
     To apprise the public of the scope of this invention, the following claims are made: