Abstract:
Systems and methods for selecting weld parameters are disclosed. An example welder interface device includes a user interface device, a processor, and a memory in communication with the processor, the memory storing machine readable instructions. The instructions, when executed, cause the processor to: identify, via the user interface device, information describing physical characteristics of a weld; based on the physical characteristics of the weld, determine operating parameters to be used by a welding system during the weld based on a model, the operating parameters including at least one of a welding process or a welding transfer mode; control the welding system based on the operating parameters; access feedback information from the welding system, the feedback information comprising a plurality of variables from the welding system; and control the welding system using updated operating parameters determined during the weld based on the feedback information

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent is a continuation of U.S. patent application Ser. No. 14/530,412, filed Oct. 31, 2014, entitled “SYSTEM AND METHOD FOR SELECTING WELD PARAMETERS,” which claims priority from and the benefit of U.S. Provisional Application Ser. No. 61/899,695, entitled “SYSTEM AND METHOD FOR SELECTING WELD PARAMETERS,” filed Nov. 4, 2013, and U.S. Provisional Application Ser. No. 61/900,198, entitled “SYSTEM AND METHOD FOR SELECTING WELD PARAMETERS,” filed Nov. 5, 2013. The entireties of U.S. patent application Ser. No. 14/530,412, U.S. Provisional Application Ser. No. 61/899,695, and U.S. Provisional Application Ser. No. 61/900,198 are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The invention relates generally to welding systems, and more particularly, to a system for selecting parameters for a welding system. 
         [0003]    A range of techniques have been developed for joining workpieces by welding operations. These include diverse processes and materials, with most modern processes involving arcs developed between a consumable or non-consumable electrode and the workpieces. Welding processes with non-consumable electrodes may include tungsten inert gas (TIG) welding processes, which employ a non-consumable tungsten electrode that is independent from the filler material. The processes are often grouped in such categories as constant current processes, constant voltage processes, pulsed processes, and so forth. However, further divisions between these are common, particularly in processes that consume an electrode to add filler metal to the weld. The process selected is highly linked to the filler material and its form, with certain processes utilizing a particular type of electrode. For example, certain types of metal inert gas (MIG) welding processes, which form part of a larger group sometimes referred to as gas metal arc welding (GMAW). 
         [0004]    In GMAW welding, an electrode in the form of a wire is consumed by the progressing weld pool, melted by the heat of an arc between the electrode wire and the workpiece. The wire is continuously fed from a spool through welding torch where a charge is imparted to the wire to create the arc. The electrode configurations used in these processes are often referred to as either solid wire, flux cored or metal cored. Each type is considered to have distinct advantages and disadvantages over the others, and careful adjustments to the welding process and weld settings may be required to optimize their performance. For example, solid wire, while less expensive than the other types, is typically used with inert shielding gases, which can be relatively expensive. Flux cored wires may not require separate shielding gas feeds, but are more expensive than solid wires. Metal cored wires do require shielding gas, but these may be adjusted to mixes that are sometimes less expensive than those required for solid wires. Shielded metal arc welding (SMAW) utilizes an electrode coated or filled with one or more compounds that produce shielding gas when the arc is struck. The properties and the cost of a weld application may be based on the welding process and weld settings utilized. Unfortunately, user selection of the welding process and the weld settings for a particular application may be complex. 
       BRIEF DESCRIPTION 
       [0005]    The welder interface described may increase synergy with the welding system for the user. The welder interface receives input parameters (e.g., physical characteristics) of a desired weld from a user and advises a weld process and weld variables (e.g., electrical parameters) for producing the desired weld. The welder interface may be integral with a component (e.g., power source, wire feeder, torch) of the welding system, or a separate component that may be coupled (e.g., wired or wireless connection) with the welding system. The welder interface may utilize data from a look-up table, neural network, welding procedure system, database, or any combination thereof to advise the weld process and weld variables. The user may utilize the welder interface to simulate the weld process and the effect of the weld variables on a simulated weld. The user may modify the input parameters and/or the weld variables prior to producing a weld, and the user may modify the weld variables after reviewing the results of the produced weld to refine the advised weld process and weld variables for subsequent welding applications. 
     
    
     
       DRAWINGS 
         [0006]    These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
           [0007]      FIG. 1  is an embodiment of a welding system and a welder interface in accordance with embodiments of the present disclosure; 
           [0008]      FIG. 2  is an embodiment of the welder interface of the welding system, in accordance with embodiments of the present disclosure; 
           [0009]      FIG. 3  is a diagrammatical view representing movement of an embodiment of an electrode relative to a workpiece of the welding system; and 
           [0010]      FIG. 4  is an embodiment of a method for utilizing the welder interface with the welding system, in accordance with embodiments of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. 
         [0012]    When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
         [0013]    Embodiments of the welding system as described herein may include a welder interface that receives input parameters (e.g., physical characteristics, weld parameters) and determines one or more welding processes and welding variables for implementing the one or more welding processes based at least in part on the received input parameters. The welder interface may be incorporated with or separate from a welding machine, an automation system, a power source, a wire feeder, a torch, a pendant, a networked device connected (e.g., wired or wirelessly) to the welding system, or any combination thereof. The welder interface may receive the weld parameters directly from a user, and/or the welder interface may determine the weld parameters from data (e.g., computer-aided design file) imported to the welder interface. The welder interface may determine the weld process and the weld parameters based on a variety of factors including, but not limited to, desired characteristics (e.g., quality, appearance, strength) of the welding application, user productivity, capital costs, operating costs, or consumable inventory, or any combination thereof 
         [0014]    Turning to the figures,  FIG. 1  is a diagram of an embodiment of a welding system  10  and a welder interface  11 , in accordance with embodiments of the present disclosure. It should be appreciated that, while the welding system  10  described herein is specifically presented as a gas metal arc welding (GMAW) system  10 , the welder interface  11  may also be used with other arc welding processes (e.g., FCAW, FCAW-G, GTAW (TIG), SAW, SMAW) or other welding processes (e.g., friction stir, laser, hybrid). In some embodiments, the weld interface  11  may be utilized to facilitate combining weld processes and energy sources into hybrid-type processes, where an arc welding process is combined with an energy source, such as a laser, induction heating device, plasma, and so forth. More specifically, as described in greater detail below, the equipment and accessories used in the welding system  10  may include the welder interface  11  described herein. The welding system  10  includes a welding power supply unit  12  (i.e., a welding power source), a welding wire feeder  14 , a gas supply system  16 , and a welding torch  18 . The welding power supply unit  12  generally supplies power to the welding system  10  and other various accessories, and may be coupled to the welding wire feeder  14  via a weld cable  20  as well as coupled to a workpiece  22  using a lead cable  24  having a clamp  26 . In the illustrated embodiment, the welding wire feeder  14  is coupled to the welding torch  18  via a weld cable  28  in order to supply welding wire and power to the welding torch  18  during operation of the welding system  10 . In another embodiment, the welding power supply unit  12  may couple and directly supply power to the welding torch  18 . 
         [0015]    In the embodiment illustrated in  FIG. 1 , the welding power supply unit  12  may generally include power conversion circuitry that receives input power from an alternating current power source  30  (e.g., the AC power grid, an engine/generator set, or a combination thereof), conditions the input power, and provides DC or AC output power via the weld cable  20 . As such, the welding power supply unit  12  may power the welding wire feeder  14  that, in turn, powers the welding torch  18 , in accordance with demands of the welding system  10 . The lead cable  24  terminating in the clamp  26  couples the welding power supply unit  12  to the workpiece  22  to close the circuit between the welding power supply unit  12 , the workpiece  22 , and the welding torch  18 . The welding power supply unit  12  may include circuit elements (e.g., transformers, rectifiers, switches, and so forth) capable of converting the AC input power to a direct current electrode positive (DCEP) output, direct current electrode negative (DCEN) output, variable polarity, or a variable balance (e.g., balanced or unbalanced) AC output, as dictated by the demands of the welding system  10  (e.g., based on the type of welding process performed by the welding system  10 , and so forth). 
         [0016]    The illustrated welding system  10  includes a gas supply system  16  that supplies a shielding gas or shielding gas mixtures to the welding torch  18 . In the depicted embodiment, the gas supply system  16  is directly coupled to the welding torch  18  via a gas conduit  32  that is part of the weld cable  20  from the welding power supply unit  12 . In another embodiment, the gas supply system  16  may instead be coupled to the welding wire feeder  14 , and the welding wire feeder  14  may regulate the flow of gas from the gas supply system  16  to the welding torch  18 . A shielding gas, as used herein, may refer to any gas or mixture of gases that may be provided to the arc and/or weld pool in order to provide a particular local atmosphere (e.g., shield the arc, improve arc stability, limit the formation of metal oxides, improve wetting of the metal surfaces, alter the chemistry of the weld deposit, and so forth). 
         [0017]    In addition, in certain embodiments, an automation system  34  may be used in the welding system  10 . The automation system  34  may include controllers and actuators to automatically control at least a portion of the welding system  10  without additional user input. In some embodiments, the automation system  34  is connected to the power source  12 , the wire feeder  14 , the torch  18 , or the workpiece  22 , or any combination thereof. The automation system  34  may be a robotic welding system that may control the relative movement between the torch  18  and the workpiece  22  according to instructions loaded to the automation system  34 . In some embodiments, the automation system  34  may control the power source  12  and/or the wire feeder  14  to control the weld process and the weld variables for a desired welding application. As discussed below, the automation system  34  may control the power source  12  and/or the wire feeder  14  based at least in part on the weld process and the weld variables determined by the welder interface  11  for the desired welding application. 
         [0018]    The welder interface  11  includes a controller  35  to facilitate processing information related to the welding system  10 . As discussed below, the user may provide input to the welder interface  11 , and the welder interface determines the weld process and/or the weld variables for a welding application based at least in part on the provided input. The controller  35  utilizes a processor  36  to execute instructions loaded to the welder interface  11  and/or stored into a memory  37  to determine the weld process and/or the weld variables. In some embodiments, the welder interface  11  is incorporated with a wire feeder control panel  38 , a power source control panel  40 , a torch control panel  42 , or any combination thereof, as illustrated by the dashed lines. Additionally, or in the alternative, the welder interface  11  may be a pendant along the weld cable  20 ,  28  or lead cable  24 . In some embodiments, the welder interface  11  may be separate from the power source  12 , the wire feeder  14 , and the torch  18 . For example, the welder interface  11  may include, but is not limited to, a computer, a laptop, a tablet, or a mobile device (e.g., cellular phone), or any combination thereof. The welder interface  11  may be connected to components of the welding system  10  through a wired connection or a wireless connection (e.g., via antennae  44 ). The connection with components of the welding system  10  may provide system information including, but not limited to, a type of power source, type of torch, or a type of wire feeder, or any combination thereof. The system information may be utilized to define processes available for the user and valid ranges for weld variables available for the user. In some embodiments, the welder interface  11  may connect with a network  46 . The welder interface  11  may receive network input, such as managerial systems, welding system presets, and user preferences. In some embodiments, the input received by the welder interface  11  from the network  46  may include, but is not limited to, welding procedure specifications (WPS), procedure qualification records (PQR), test files, preferred vendor lists, preferred weld systems, a sensed welding system, part numbers, direct costs data, indirect cost data, preferred process information (e.g., MIG vs. TIG), CAD files, look-up tables, neural network data, user profiles. The welder interface  11  may transmit network output (e.g., operating history, user profiles, modified models) to the network  46 . The network  46  may include, but is not limited to, a local network, a fleet network, an Internet-based resource (e.g., web page), or a cloud-based resource, or any combination thereof. As may be appreciated, the welder interface  11  may utilize information from the network  46 , the welding system  10 , and/or the user to establish presets and/or preferences for particular weld processes or weld variables. For example, a user may enter a preferred gas mixture and/or wire type to the welder interface  11 , and the welder interface will advise the weld process and weld variables based at least in part on these preferences. Additionally, or in the alternative, the user may configure the welder interface  11  to restrict advised weld processes to one of an automated MIG process, an automated TIG process, or a manual MIG process. Moreover, a user may input a hybrid process, as discussed above, as a preferred process. Hybrid processes may enable the user to utilize the welding system to overcome limitations of a particular process through modeling the behavior of the particular process for the user for better understanding of the particular process and/or combining additional processes to overcome the limitations. For example, a friction stir process alone may be less suitable for a steel workpiece; however, the welder interface  11  may advise combining induction heating or a laser process with the friction stir process to allow the workpiece to plasticize, thereby increasing the suitability of the friction stir process. Additionally, or in the alternative, filler material may be added into the stir of the friction stir process to fill into the joint or to decrease the resistance on the stir rotation. 
         [0019]      FIG. 2  illustrates an embodiment of a graphical user interface (GUI)  50  of the welder interface  11 . In some embodiments, the GUI  50  is displayed on a touch screen, thereby enabling the user to manually input information directly to the welder interface  11 . Additionally, or in the alternative, the GUI  50  may be utilized with accessories coupled to the welder interface  11 , such as buttons, dials, knobs, switches, etc. The GUI  50  enables the user to specify input parameters (e.g., physical characteristics) for a weld which the user will be making or reviewing. The input parameters may include, but are not limited to, weld joint configurations, weld position, welding materials, and weld bead parameters. As discussed below, the welder interface  11  may advise a weld process and corresponding weld variables based at least in part on physical characteristics for the weld with or without specifying electrical parameters (e.g., voltage, current, polarity, pulse duration), thereby simplifying the set-up and preparation of the welding system  10  prior to performing the weld. The welder interface  11  may advise a weld process with no welding variables specified as input characteristics, only some (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) welding variables specified as input characteristics, or substantially all of the relevant weld variables specified as input characteristics. In some embodiments, the welder interface  11  may improve the quality and/or the repeatability of a weld regardless of the experience level of the user. Based on the input parameters, the controller  35  of the welder interface  11  determines the weld process and weld variables (e.g., electrical parameters) which may be used to set the power source  12 , the wire feeder  14 , and/or the torch  18  to perform the desired welding application. In some embodiments, the processor  36  executing the GUI  50  may automatically set the weld process and weld variables in the power source  12 , the wire feeder  14 , and/or the torch  18 . Alternatively, the GUI  50  may display the determined weld process and weld variables to the user for approval or modification prior to setting the power source  12 , the wire feeder  14 , and/or the torch  18 . 
         [0020]    GUI  50  is shown having a weld type and position selection menu  52 . For example, the user may specify a butt joint, a corner joint, an edge joint, a lap joint, a tee joint, or other weld joint type. Additionally or in the alternative, the user may specify a flat position, a horizontal position, a vertical position, or an overhead position. In some embodiments, weld type and position selection menu  52  of the GUI  50  has radio buttons to specify the type and position, though it is appreciated that other conventions such as check boxes, drop-down boxes, or tabs may be used equivalently. When a user selects a weld type and/or position option, such as a butt joint and flat position, a weld depiction window  54  of the GUI  50  may display a generalized or simulated view of the type and position of joint which has been selected. 
         [0021]    The user may specify the type of workpiece material(s) via a drop down menu  56 . Thus, the GUI  50  may be programmed to present a list of material types, such as various alloys, grades, and types of metals. In certain embodiments, the GUI  50  may be pre-programmed to present only common or user-preferred material types. The GUI  50  may be further programmed to automatically set default selections for each weld type or position. As an example,  FIG. 2  illustrates the selection of a  309  Stainless Steel workpiece material. Similarly, the GUI  50  permits the user to select a thickness of the workpiece(s). For example, the GUI  50  may display in a drop down menu  58 , a number of preferred or common material thickness options for the material type selected in the drop down menu  56 . When the operator selects a workpiece material and thickness, the weld depiction window  54  of the joint can be automatically updated to reflect the chosen characteristics. 
         [0022]    The GUI  50  may include boxes to enable the user to describe other characteristics of the joint and/or the weld itself. For example, the user may enter values for input parameters including, but not limited to, a desired fillet size  62 , a desired penetration depth  64 , a penetration profile  66 , a bead width  68 , a bevel width  70 , a gap width  72 , a joint length  74 , a bevel angle, or any combination thereof In some embodiments, the user may manually enter the desired characteristics, rather than selecting them from menus. It may be appreciated, however, that other GUI conventions, such as menus and checkboxes may be used for inputting characteristics, or a click-and-drag type scalable control could be included in the GUI for increasing/decreasing a parameter value, such as the bead width  68 . The specified characteristics may be shown in the weld depiction window  54 , and the weld depiction window  54  may be modified as the characteristic values are adjusted. As may be appreciated, the user may readily determine the physical characteristics from a brief observation of the joint or a joint specification in a manual, whereas the determination of the weld process type and the weld variables (e.g., electrical parameters) for a weld application may be a more complex process. That is, the user may understand the physical characteristics of joint for the weld application regardless of the welding experience level of the user, whereas the understanding of the desired process and the weld variables for the desired weld application may increase with user experience. In embodiments for which the welder interface  11  may specify a GMAW welding process, the GUI  50  may also present inputs for wire type  78 , wire feed speed  80 , shielding gas type  82 , spin or weave pattern  84 , or travel speed  86 , or any combination thereof. The user may leave one or more of the input parameters blank (e.g., no input parameter value), and the welder interface  11  may determine an advised value or range of values. 
         [0023]    In some embodiments, the user may import preset joint characteristics and/or electrical parameters for a desired weld by selecting an import button  88 . The import button  88  may enable the user to retrieve previously saved sets of joint characteristics from local memory storage (e.g., memory  37 ), or to input joint characteristics from an outside data source (e.g., network  46 ). For example, the joint characteristics may be uploaded directly from a CAD file or other architectural or engineering specification, a laptop computer, a mobile device, or a computer network. In other words, the welder interface  11  may download or receive data from a schematic specification file from a computing-type device and use such data to determine the joint characteristics and/or electrical parameters. The weld depiction window  54  may present a model  89  of the imported data (e.g., CAD file). In some embodiments, the GUI  50  may enable the user to modify the imported data. Additionally, or in the alternative, the user may control the weld depiction window  54  to change the model  89  of the imported data. In some embodiments, a simulate button  90  may enable the GUI  50  to display a simulation of the weld formation and/or the completed weld. The user may utilize the GUI  50  to manipulate the view and/or playback of the simulation. As may be appreciated, the simulation enables the user to preview an advised weld process, which may aid the user in performing the weld process. Additionally, or in the alternative, the user may modify the weld process and/or the weld variables upon observation of the simulation in order to change the result of the weld process from the simulated result. The user may utilize the simulations to review potential tradeoffs between related weld variables. For example, increasing the travel speed may decrease penetration and/or narrow the weld bead profile, whereas decreasing the travel speed may increase the penetration and/or widen the weld bead profile. Moreover, increasing a size of a spin and/or weave pattern may widen the weld bead profile and/or decrease penetration, and decreasing the size of a spin and/or weave pattern may narrow the weld bead profile and/or increase penetration. In some embodiments, a store settings button  92  may be used to create stored sets of characteristics (e.g., physical, electrical) from the current settings displayed by the GUI  50 . These sets of characteristics may be stored in memory  37  and/or on the network  46 , and may be retrieved for later use via the import button  88 . 
         [0024]    The GUI  50  includes command buttons to process the one or more user specified input parameters. The user may select an advise button  94  to control the welder interface  11  to determine one or more weld processes and weld variables to facilitate formation of the desired weld based at least in part on the specified input parameters. The GUI  50  will display the one or more weld processes and weld variables (e.g., electrical parameters) by which to set the power source  12 , the wire feeder  14 , and/or the torch  18 . These weld variables may include, but are not limited to, a weld process  96 , a power source voltage setting  98 , a power source current setting  100 , a power source frequency  102 , a polarity  104 , and an operation mode  106  (e.g., constant current CC, constant voltage CV, or pulse). The weld process  96  may include, but is not limited to, FCAW, FCAW-G, GTAW (TIG), SAW, SMAW, friction stir, laser, hybrid, or any combination thereof. In some embodiments, the weld variables determined by the welder interface  11  may include wire parameters (e.g., wire type  78 , wire diameter, wire feed speed  80 , quantity of wires), torch parameters (e.g., quantity of passes, weave width, spin and/or weave pattern  84 , longitudinal torch travel speed  86 , electrode spin speed, electrode extension speed, electrode retraction speed, travel angle, work angle), gas type  82 , current changes over time (e.g., current ramp rates), voltage changes over time (e.g., voltage ramp rates), joules, pulse duration, induction heating temperature, or added laser energy, or any combination thereof. As discussed below, the welder interface  11  may utilize information from managerial preferences, user preferences, or other preferences, to determine the advised weld process and the weld variables. In some embodiments, the welder interface  11  may utilize information (e.g., reference data) from a welding procedure specification (WPS), a look-up table, a network database, or a neural network, or any combination thereof, to determine the advised weld process and the weld variables. 
         [0025]    As may be appreciated, upon selection of the advise button  94 , the welder interface  11  may determine any of the input parameters left blank (e.g., no input value provided). The GUI  50  may also enable the user to alter previously-selected input parameters (e.g., physical characteristics) and have the GUI  50  re-determine the weld process and the weld variables by selection of a refresh button  108 . In some embodiments, the one or more weld processes and the weld variables determined by the welder interface  11  for the user may be displayed on one or more screens to be reviewed by the user. Upon review of the advised weld process and corresponding weld variables, the user may modify the advised determinations via selection of a modify button  110 . For example, the user may modify one or more weld variables (e.g., wire feed speed  80 , voltage  98 , frequency  102 ) while maintaining at least some of the advised weld variables or input parameters. After modification (if any) of the weld variables or input parameters, the user may approve of the weld process and the weld variables via selection of an approve button  112 , thereby enabling the welder interface  11  to control the power source  12 , the wire feeder, and/or the torch  18  to perform the weld application with the advised weld process and the advised weld variables. 
         [0026]    In some embodiments, an economics button  114  enables the user to review various economic factors for the advised weld process and weld variables. The cost of performing a welding application may be based at least in part on the cost of consumables (e.g., welding wire, contact tip, shielding gas, electrode), energy costs, labor costs, facility costs, equipment costs. For example, forming a weld for a deep groove application with relatively large wire diameter welding wire may have lower labor costs than forming the weld in the deep groove application with a relatively small wire diameter welding wire because of an increased number of passes to form the weld. Additionally, a flux cored or metal cored electrode may have a greater consumable cost than a solid electrode for some applications; however, the labor cost and/or shielding gas cost may be less for the flux cored or metal cored electrode than a solid electrode for other applications. Moreover, some weld processes (e.g., TIG processes, advanced weld processes, hybrid weld processes) may be associated with higher labor costs than other weld processes (e.g., SMAW processes, MIG processes), where higher labor costs may be based at least in part on greater operator skill level. Facility costs may include, but are not limited to, costs associated with maintenance and supply costs for the automation system  34  that may execute the weld process. Equipment costs may include, but are not limited to, costs associated with procurement of components of the welding system  10 . User selection of the economics button  114  may display data that provides approximate costs for weld processes that may be utilized for the desired welding application. Accordingly, the welder interface  11  may advise a weld process and weld variables based at least in part on economic factors, such as cost. 
         [0027]      FIG. 3  illustrates an embodiment of movement of the torch  18  and an electrode  120  relative to the workpiece  22 . The welder interface  11  may determine weld variables that may include variables that describe movement of the torch  18  and/or an electrode  120  relative to the workpiece  22 .  FIG. 3  illustrates some of the weld variables that describe the arrangement of the torch  18 , the electrode  120 , and the workpiece  22  relative to one another during a weld. The torch  18  and the electrode  120  move in a longitudinal travel direction  122  along a joint  124  between the workpiece materials  22 . As the electrode  120  moves along the joint  124 , the weld is formed as portions of the electrode  120  are deposited onto the workpiece  22  and/or onto previously deposited electrode material (e.g., weld pool). The electrode  120  may move in a transverse direction  126  and/or an axial direction  128  relative to the joint  124 . The movement of the torch  18  and the electrode  120  in the transverse direction  126  may be defined herein as a weave pattern. The dashed lines  127  illustrate an embodiment of the movement (e.g., oscillation) of the torch  18  within the weave pattern across the joint  124 . A work angle  130  describes the angle between an axis  132  of the electrode  120  and the joint  124  along the transverse direction  126 . A torch angle  134  describes the angle between the axis  132  of the electrode and the joint  124  along the longitudinal direction  122 . 
         [0028]    In some embodiments, the electrode  120  may be moved (e.g., spun) in a desired pattern relative to the torch  18  while the torch  18  moves in the longitudinal travel direction  122 . The electrode  120  may spin within the joint  124 , as shown by arrow  136 , thereby increasing the area in which the electrode material may be deposited within the joint  124 . The electrode  120  may be moved in a variety of patterns including, but not limited to, a circle, an ellipse, a zigzag, a  FIG. 8 , a transverse reciprocating line, a crescent, a “C” shape, a “J” shape, a “T” shape, a triangle, a square, a rectangle, a non-linear pattern, an asymmetrical pattern, a pause, or any combination thereof. Such movement patterns and applications of the movement patterns are described in U.S. Provisional Patent Application No. 61/878,404, entitled “Synchronized Rotating Arc Welding Method and System,” filed by Christopher Hsu et al. on Sep. 16, 2013, which is hereby incorporated into the present disclosure by reference. 
         [0029]    The torch  18  and/or the electrode  120  may be moved along the axis  132  to control the deposition of the electrode material into the joint  124 . In some embodiments, user may utilize multiple passes of the torch  18  and the electrode  120  along the joint  124 , with each pass forming a layer such that the completed weld has multiple layers in a vertical direction  138 . Additionally, or in the alternative, the weld process may control the movement (e.g., extension, retraction) of the electrode  120  along the axis  132  relative to the torch  18 . For example, the electrode  120  movement along the axis  132  may be controlled to affect the deposition rate of the electrode material and/or the heat applied to the workpiece. In some embodiments, the movement of the electrode  120  along the axis  132  may be controlled with the desired movement pattern (e.g., arrow  136 ) to control the deposition location of the electrode material. 
         [0030]      FIG. 4  illustrates an embodiment of a method  150  for utilizing the welder interface  11  for determination of a weld process and weld variables. The welder interface  11  receives (block  152 ) input parameters (e.g., physical characteristics) from the user. The input parameters may be received via manual input through the GUI  50  and/or automatically via importation of data (e.g., CAD file) as described above. Based at least in part on the received input parameters, the welder interface  11  determines (block  154 ) at least one weld process and determines (block  156 ) weld variables for the at least one weld process. The welder interface  11  then displays (block  158 ) the results of the determined one or more weld processed and the weld variables to the user for review and approval. In some embodiments, the results may be displayed via a simulation of the weld process and/or the completed weld. 
         [0031]    The welder interface  11  utilizes the received input parameters and determines the weld process (block  154 ) and the weld variables (block  156 ) utilizing data stored in the memory  37  and/or the network  46 . The data stored in the memory  37  and/or the network  46  may relate various factors associated with weld processes and weld variables. For example, the determination of a particular weld process and the weld variables for the weld process may be based at least in part on the applicability (e.g., economics, quality, strength, appearance) of the weld process for various physical characteristics of the desired weld. The applicability of the determined weld process may include, but is not limited to, the economics (e.g., costs) of the determined weld process and weld variables, the user skill level, complexity of the determined weld process, welding systems available to the user, inventory available to the user, and user productivity/efficiency. The data stored in the memory  37  and/or the network  46  may be in the form of a look-up table, a neural network, a network database, managerial system, presets, and preferences to include a welding procedure specification (WPS), or any combination thereof. In some embodiments, the manufacturer and/or the user may populate data sets to be loaded into the memory  37  and/or the network  46  for a variety of weld processes. For example, TIG welding may be advised for a welding application with relatively thin workpiece materials and/or with aluminum alloys, and MIG welding may be advised for a welding application with relatively thick workpiece materials and/or for open root applications. In some embodiments, a friction stir and/or a hybrid process may be advised for a relatively flat bead profile and/or to increase heating to the workpiece  22 . 
         [0032]    Upon display (block  158 ) of the advised weld process and the weld variables, the user decides (node  160 ) whether to accept the advised weld process and weld variables or to revise (block  162 ) the input provided to the welder interface to potentially generate a different advised weld process and weld variables. In some embodiments, the user may revise the input parameters (e.g., physical characteristics) provided to the welder interface  11 . Additionally, or in the alternative, the user may add or remove input parameters (e.g., physical characteristics, electrical parameters) provided to the welder interface  11 . As may be appreciated, the display (block  158 ) of the advised weld process and the weld variables may include the welder interface  11  simulating the advised weld process. The welder interface  11  may display the simulation at various speeds (e.g., real time, slow motion) and various views or orientations (e.g.,  2 D,  3 D). Moreover, the welder interface  11  may display a simulation of the dynamics of the simulated weld from different perspectives, such as a close view illustrating the dynamics of the electrode and weld pool, or a component view (e.g., cross-sectional view) illustrating the effect on the joint and/or workpiece as a whole. The simulations displayed by the welder interface  11  may include, but are not limited to, simulated wire placement in the joint or weld pool, visual wire feed speed changes, graphs of predicted (e.g., simulated) current and voltage, puddle agitation, spatter levels, other effects, or any combination thereof. 
         [0033]    When the user agrees to the advised weld process and the weld variables, the welder interface  11  may control (block  164 ) the components (e.g., power source  12 , wire feeder  14 , torch  18 ) of the welding system  10  to enable the user and/or the automation system  34  to perform the desired welding application. For example, the welder interface  11  may control the wire feeder  14  with the advised wire feed speed for an advised MIG welding process, and the welder interface  11  may set the voltage, current, and pulse parameters of the power source  12  for the advised MIG welding process. Upon completion of the weld, the user and/or the welder interface  11  may review the weld and generate results (e.g., scores) regarding observable qualities of the weld. For example, the user may review aspects of the appearance of the weld, such as bead width, bead spacing, penetration, burn through, porosity, cracks, and so forth. Additionally, or in the alternative, the user or the welder interface  11  may review aspects of the weld history, such as the voltage waveform, the current waveform, or filler metal (e.g., welding wire) utilized. The welder interface  11  may receive (block  166 ) results from the user to facilitate comparing (block  168 ) the results of the actual weld to prior results and/or to simulated results. Based at least in part on the comparison, the welder interface  11  may adjust (block  170 ) models in the memory  37  and/or on the network  46  that were utilized to advise the weld process and the weld variables. 
         [0034]    In some embodiments, the method  150  described above may be utilized iteratively to populate data (e.g., models) for a look-up table, database, or neural network. For example, the user may initially only input the physical characteristics as input parameters, and the user may subsequently revise the input parameters to specify a particular weld process (e.g., TIG, MIG, SMAW) or a set of one or more electrical parameters (e.g., voltage, current, frequency, polarity, wire feed speed) to change properties of the resulting weld. The user may utilize the method  150  to determine the effect of adjusting one or more weld variables (e.g., electrical parameters), while maintaining or managing some level of change to the weld process and physical characteristics. This enables the user to modify the data to approximate variations that may occur during actual weld formation that may not be otherwise accounted for during a simulation of the weld. As another example, the user may modify the weld variables for the spin and/or weave patterns alone or in combination with the voltage, current, wire feed speed, and travel speed to control the deposition location of the electrode material to the weld. Additionally, or in the alternative, the weld current may be modified to control spray and/or spatter of electrode material, the weld voltage may be modified to control penetration, or travel speed may be modified to control the fluidity of the weld pool. In some embodiments, iterative modification of the weld variables utilizing the welder interface  11  enables the user to generate robust models that may be utilized to advise a weld process and weld variables with relatively complex timing, speed, and energy levels to generate a desired weld even when the user provides relatively simple input parameters (e.g., physical characteristics). 
         [0035]    The welder interface  11  may recommend the weld variables based on user preferences incorporated into the models. In some embodiments, the welder interface  11  may enable the welding system  10  to control the penetration depth to reduce or eliminate burn through of the workpiece  22 . As may be appreciated, AC processes may be utilized to manage deposition and/or burn through. The welder interface  11  may advise a particular polarity to be utilized at certain points within the joint. For example, positive polarity when weaving the torch  18  over a seam may increase penetration, and negative polarity when weaving the torch  18  over the sidewalls of the joint may enable the workpiece materials to cool more than under a positive polarity. Additionally, or in the alternative, the welder interface  11  may advise one or more pauses to alter the penetration in conjunction with the wire feed speed to adjust the penetration depth of the weld. In some embodiments, welder interface  11  may advise a combination of one or more weld processes (e.g., controlled short circuit process in a first portion, an AC process in a second portion, and a pulse process in a third portion) to manage the penetration of a weld into the joint. The welder interface  11  may utilize feedback (e.g., sensor feedback) from the welding system  10  to modify the weld process and/or the weld variables in substantially real-time. For example, the welder interface  11  may utilize position and/or motion feedback of the torch  18  and the electrode  120  relative to the workpiece  22  to control the timing of adjustments to weld variables. 
         [0036]    In some embodiments, the models stored in memory  37  and/or the network  46  may be based at least in part on a volumetric calculation of deposited filler material, thermal dynamics of the welding application, and/or fluid dynamics of the molten filler material. For example, the welder interface  11  may advise a weld process with a deposition rate, travel speed, and wire feed speed that would deposit a volume of filler material (e.g., welding wire) that would fill the joint with a desired density/porosity. The welder interface  11  may be configured to advise the weld process based at least in part on forces acting on the filler material prior to solidification with the workpiece. For example, the welder interface  11  may advise the weld process based at least in part on the weld position, gravity, centrifugal forces on the molten filler material due to the conventional wire placement, weave of the torch and/or spin of the electrode, or any combination thereof. 
         [0037]    The models utilized by the welder interface  11  may incorporate thresholds to maintain the advised weld process and the advised weld variables within desired economic bounds. For example, the welder interface  11  may be configured to advise a welding process with the lowest cost that satisfies the specifications for the desired weld. Additionally, or in the alternative, the welder interface  11  may be configured to advise welding processes that are within a range of skill levels to increase the reproducibility and the quality of the welds performed by users utilizing the welder interface  11 . In some embodiments, when multiple weld processes may be capable of producing a desired weld based on the input parameters, the welder interface  11  may advise a weld process that has a lower cost and/or a lower complexity relative to other the capable weld processes. 
         [0038]    The welder interface described above may increase synergy with the welding system for the user. The welder interface receives input parameters (e.g., physical characteristics) of a desired weld from a user and advises a weld process and weld variables (e.g., electrical parameters) for producing the desired weld. The welder interface may be integral with a component (e.g., power source, wire feeder, torch) of the welding system, or a separate component that may be coupled (e.g., wired or wireless connection) with the welding system. The welder interface may utilize data from a look-up table, neural network, welding procedure system, database, or any combination thereof to advise the weld process and weld variables. As described above, the user may utilize the welder interface to simulate the weld process and the effect of the weld variables on a simulated weld. The user may modify the input parameters and/or the weld variables prior to producing a weld, and the user may modify the weld variables after reviewing the results of the produced weld to refine the advised weld process and weld variables for subsequent welding applications. In some embodiments, the welder interface may control the weld process and the weld variables in real time to control the results to a modeled result. For example, when welding a pipe root pass, the welder interface may receive feedback from a spin torch on the location of the wire placed in the joint via an encoder, tachometer, or other sensor. The feedback to the welder interface enables the welder interface to control the welding system to modulate the wire feed speed, the spin speed, the electrical parameters, or any combination thereof, to reduce or eliminate burn through. The welder interface may sense burn through or an impending burn through via sensing the voltage, current, visual appearance of the weld, or an audible sound of the weld, or any combination thereof. The welder interface may track the movement of the wire within the joint via observation of the voltage and spin as the wire rotates within the joint. In some embodiments, the welder interface may deliver the advised weld process and weld variables in real time to one or more welding systems at a work site, thereby enabling the one or more welding systems to be utilized for the advised weld process. Moreover, the welder interface may display the voltage, current, wire feed speed, and other weld variables on graphs, charts, or oscilloscope formats, or any combination thereof. 
         [0039]    While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.