Patent ID: 12194574

DETAILED DESCRIPTION

The examples and figures herein are illustrative only and are not meant to limit the subject invention, which is measured by the scope and spirit of the claims. Referring now to the drawings, wherein the showings are for the purpose of illustrating exemplary embodiments of the subject invention only and not for the purpose of limiting same,FIG.1illustrates a block diagram of one embodiment of an arc welding system100configured to provide a short circuit arc welding process having improved performance stability.

The welding system100includes a power conversion circuit110providing welding output power between a welding electrode E and a work piece W. The power conversion circuit110may be transformer based with a bridge output topology (e.g. a half bridge output topology). For example, the power conversion circuit110may be of an inverter type that includes an input power side and an output power side as delineated by the primary and secondary sides, respectively, of a welding transformer. Other types of power conversion circuits are possible as well such as, for example, a chopper type have a DC output topology. A wire feeder5feeds the consumable wire welding electrode E toward the work piece W. The wire feeder5, the consumable welding electrode E, and the work piece W can be considered to be a part of the welding system100and are operatively connected to other parts of the system100via, for example, welding output cables.

The welding system100also includes a waveform generator120and a controller130. The waveform generator120generates welding waveforms (e.g., a short circuit welding waveform) at the command of the controller130. A waveform generated by the waveform generator120modulates the output of the power conversion circuit110to produce the welding output current between the electrode E and the work piece W. The welding system100also includes a voltage feedback circuit140and a current feedback circuit150to monitor the welding output voltage and current between the electrode E and the work piece W and provide the monitored voltage and current back to the controller130. The feedback voltage and current may be used by the controller130to make decisions with respect to modifying the welding waveform generated by the waveform generator120and/or to make other decisions that affect safe operation of the welding system100. For example, the controller130may use the feedback voltage and/or the feedback current to determine when a short of the electrode E to the work piece W has occurred, and when a molten metal ball on the tip of the electrode E is about to pinch off from the tip of the electrode E and into a weld puddle (pool) on the work piece W.

FIG. 4 of U.S. Pat. No. 5,001,326, which is incorporated herein by reference, is referred to, in order to establish some definitions. Referring to FIG. 4 of U.S. Pat. No. 5,001,326, a short circuit welding waveform is shown. The short circuit welding waveform could be produced by the arc welding system100ofFIG.1herein. The waveform includes (with respect to welding output current) a background phase, a pinch phase, a peak phase, and a tail-out phase. In between the background phase and the pinch phase is a first low current transition section. Also, in between the pinch phase and the peak phase is a second low current transition section. During a welding operation using the waveform of FIG. 4 of U.S. Pat. No. 5,001,326 (e.g., as produced by the welding system100ofFIG.1herein), a molten metal ball is produced at the tip of the welding electrode E during the background phase. During the first low current transition section, the molten metal ball shorts to the work piece W and the current is reduced, allowing the molten metal ball to wet into the weld puddle on the work piece W. During the pinch phase, a dual ramp pinch current is applied to the short to help the molten metal ball pinch off from the end of the electrode E into the weld puddle on the work piece W. There is a break point (BP) between the dual ramps of current of the pinch phase and there is a necking threshold current level near the end of the pinch phase, as discussed later herein. During the second low current transition section, the current is reduced, allowing a welding arc to easily re-establish between the electrode E and the work piece W after the molten metal ball has pinched off from the electrode E, clearing the short. During the peak phase, peak current is applied to set the proper arc length of the re-established arc and to begin melting a new molten metal ball from the tip of the electrode E. During the tail-out phase, generated heat is controlled by controlling the rate at which the current transitions from a peak current level to a background current level of the next background phase. The waveform repeats during the welding process to form a weld.

Referring again to FIG. 4 of U.S. Pat. No. 5,001,326, the term “pinch phase”, as used herein, refers to the portion of a short circuit arc welding waveform where a “pinch pulse” (PP) welding output current is produced. The pinch phase is entered when a molten metal ball on the tip of a welding electrode first shorts to a work piece, and ends when the molten metal ball pinches off from the tip of the welding electrode and enters the weld puddle (pool). During the pinch phase, the welding current of the PP is controlled to initially ramp (e.g., upwards) at a first rate (having a first steep slope) towards a break point (BP), as seen in FIG. 4 of U.S. Pat. No. 5,001,326. Once the break point (BP) is reached, the welding current of the PP is controlled to ramp (e.g., further upwards) at a second rate (having a second gradual slope) where the welding current eventually reaches a necking threshold level (e.g., a peak level of the PP) before dropping, as seen in FIG. 4 of U.S. Pat. No. 5,001,326.

Therefore, the break point (BP) is that point during the pinch phase where the welding current is transitioned from the first steep slope to the second gradual slope. At the break point (BP), the welding output is said to be at a BP welding current level or a BP welding energy level (e.g., a surface tension transfer (STT) pinch current level). For example, an STT switch may be part of the power conversion circuit110to help effect the break point. The necking threshold is the point where a short exit detection is triggered (a premonition of a short exit), indicating that the molten metal ball is about to pinch off from the tip of the welding electrode and enter the weld puddle (pool). At the necking threshold, the welding output is said to be at a necking threshold current level (or a necking threshold energy level).

The term “energy” is used broadly herein (e.g., when referring to a value of necking threshold, a value of break point, and values of certain pinch calculations using same). To the extent that energy is proportional to current and power (where an increase in current can correspond to an increase in energy or power, and where a decrease in current can correspond to a decrease in energy or power), the term “energy” may refer to energy, current, or power. Also, standard units of energy and/or current and/or power do not necessarily have to be used with respect to all aspects of certain embodiments of the present invention, as long as a relative consistency is maintained. For example, a scaled version of current (amps) may be used to represent power or energy. What matters are the relationships of the parameter values (e.g., necking threshold value, break point value, actual pinch value, specified pinch value) with respect to each other, as discussed in more detail later herein.

In accordance with one embodiment, the controller130of the arc welding system100monitors and stores a necking threshold energy in the form of data points. The stored necking threshold energy is put through a rolling average of previous short circuit energy captures and is then used to determine a relationship with respect to a break point (BP) energy to form a pinch energy relationship (e.g., as a ratio or a percentage). A value of the real time (actual) pinch energy relationship is compared to a previously specified and desired pinch energy relationship value stored in a weld table (e.g., in a memory of the controller130). Based on the result of the comparison, the break point (BP) energy is adjusted to drive the pinch energy relationship to the desired value. This provides consistent stability for the short circuit welding process, even while welding parameters are changing during the welding process.

FIG.2illustrates one embodiment of a portion of a short circuit arc welding waveform200, produced by the system100ofFIG.1for the short circuit welding process, showing a break point210and a necking threshold220. The BP210and the necking threshold220are each points on the pinch pulse within the pinch phase230. The pinch phase230has a first steep slope portion205(a first ramp) and a second gradual slope portion215(a second ramp) as seen inFIG.2. A peak pulse, occurring during a peak phase240after the pinch pulse, is also shown. In accordance with one embodiment of the present invention, it is the break point210which is automatically and dynamically adjusted upwards or downwards (corresponding to a break point energy being automatically adjusted upwards or downwards) to maintain the actual pinch energy to be at a specified pinch energy. In accordance with one embodiment, the necking threshold energy is determined from at least one of the welding current and the welding voltage of the short circuit arc welding waveform output at the necking threshold, and the break point energy is determined from at least one of the welding current and the welding voltage of the short circuit arc welding waveform output at the break point (e.g., as monitored by the voltage feedback circuit140and/or the current feedback circuit150).

The actual pinch energy is expressed as a pinch energy relationship value, and the specified pinch energy is expressed as a specified pinch energy relationship value. The relationship is between the necking threshold energy and the break point energy. In accordance with one embodiment, the pinch energy relationship value is calculated (e.g., by the controller130) as a ratio of the running average (RA) of the necking threshold energy and the break point energy, as follows:
Pinch Energy=RANecking Threshold Energy/Break Point Energy.

In accordance with one embodiment, the pinch energy relationship value is calculated (e.g., by the controller130) as a percentage from the running average of the necking threshold energy and the break point energy, as follows:
Pinch Energy (%)=(RANecking Threshold Energy/Break Point Energy)×100
or
Pinch Energy (%)=(Break Point Energy/RANecking Threshold Energy)×100.

In accordance with one embodiment, the pinch energy relationship value is calculated (e.g., by the controller130) as a difference between the running average of the necking threshold energy and the break point energy, as follows:
Pinch Energy=RANecking Threshold Energy−Break Point Energy.

In accordance with one embodiment, the pinch energy relationship value is calculated (e.g., by the controller130) as a difference between the running average of the necking threshold energy and the break point energy, normalized to the running average of the necking threshold energy, as follows:
Pinch Energy=(RANecking Threshold Energy−Break Point Energy)/RANecking Threshold Energy.

In accordance with one embodiment, the pinch energy relationship value is calculated (e.g., by the controller130) as a difference between the running average of the necking threshold energy and the break point energy, normalized to the break point energy, as follows:
Pinch Energy=(RANecking Threshold Energy−Break Point Energy)/Break Point Energy.

Other ways of calculating a Pinch Relationship Energy (using a RA Necking Threshold Energy and a Break Point Energy) are possible as well, in accordance with other embodiments. Furthermore, in one embodiment, instead of a running average, a sliding window average of necking threshold values (e.g., energy values) over N samples may be used instead (N being a positive integer). Other types of averages of necking threshold values (and/or break point values) may be used, in accordance with other embodiments.

Again, the term “energy” is used broadly herein (e.g., when referring to a value of necking threshold, a value of break point, and values of certain pinch calculations using same). To the extent that energy is proportional to current and power (where an increase in current can correspond to an increase in energy or power, and where a decrease in current can correspond to a decrease in energy or power), the term “energy” may refer to energy, current, or power. Also, standard units of energy and/or current and/or power do not necessarily have to be used with respect to all aspects of certain embodiments of the present invention, as long as a relative consistency is maintained. For example, a normalized version of watts (amps×volts) may be used to represent power or energy. What matters are the relationships of the parameter values (e.g., necking threshold value, break point value, actual pinch value, specified pinch value) with respect to each other.

FIG.3illustrates how a welding output voltage310, a welding output current320, and a welding output resistance330behave near the necking threshold of the short circuit welding waveform output, in accordance with one embodiment. A short exists between the welding electrode and the work piece just before the necking threshold. Just after the necking threshold, the short is exited or cleared and an arc is re-established between the welding electrode and the work piece.

FIG.4illustrates a flow chart of one embodiment of a method400for providing improved stability in a short circuit arc welding process by dynamically adjusting a break point (BP) during welding. In block410of the method400, a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, is generated between a welding electrode and a work piece during a short circuit arc welding process. In block420, a necking threshold energy of the short circuit arc welding waveform output is monitored during the short circuit arc welding process and a running average of the necking threshold energy is generated. Again, the necking threshold energy corresponds to an energy at the necking threshold in the pinch phase where a premonition of a short exit is detected, indicating that a molten metal ball is about to pinch off from a tip of the welding electrode and enter a weld puddle on the work piece. In block430, a break point energy of the short circuit arc welding waveform output is monitored during the short circuit arc welding process. Again, the break point energy corresponds to an energy at the break point in the pinch phase where a current of the short circuit arc welding output is transitioned from a first steep slope to a second gradual slope. In block440, an actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy. In block450, the actual pinch energy relationship value is compared to a previously specified pinch energy relationship value. In block460, the break point energy of the short circuit arc welding waveform output is adjusted in response to the comparing to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value. In this manner, improved and consistent stability for the short circuit welding process is achieved, even while welding parameters are changing during the welding process.

FIG.5illustrates a block diagram of an example embodiment of a controller500that can be used, for example, as the controller130in the arc welding system100ofFIG.1. Referring toFIG.5, the controller500includes at least one processor514(e.g., a microprocessor, a central processing unit, a graphics processing unit) which communicates with a number of peripheral devices via bus subsystem512. These peripheral devices may include a storage subsystem524, including, for example, a memory subsystem528and a file storage subsystem526, user interface input devices522, user interface output devices520, and a network interface subsystem516. The input and output devices allow user interaction with the controller500. Network interface subsystem516provides an interface to outside networks and is coupled to corresponding interface devices in other devices.

User interface input devices522may include a keyboard, pointing devices such as a mouse, trackball, touchpad, or graphics tablet, a scanner, a touchscreen incorporated into the display, audio input devices such as voice recognition systems, microphones, and/or other types of input devices. In general, use of the term “input device” is intended to include all possible types of devices and ways to input information into the controller500or onto a communication network.

User interface output devices520may include a display subsystem, a printer, or non-visual displays such as audio output devices. The display subsystem may include a cathode ray tube (CRT), a flat-panel device such as a liquid crystal display (LCD), a projection device, or some other mechanism for creating a visible image. The display subsystem may also provide non-visual display such as via audio output devices. In general, use of the term “output device” is intended to include all possible types of devices and ways to output information from the controller500to the user or to another machine or computer system.

Storage subsystem524stores programming and data constructs that provide some or all of the functionality described herein. For example, computer-executable instructions and data are generally executed by processor514alone or in combination with other processors. Memory528used in the storage subsystem524can include a number of memories including a main random access memory (RAM)530for storage of instructions and data during program execution and a read only memory (ROM)532in which fixed instructions are stored. A file storage subsystem526can provide persistent storage for program and data files, and may include a hard disk drive, a solid state drive, a floppy disk drive along with associated removable media, a CD-ROM drive, an optical drive, or removable media cartridges. The computer-executable instructions and data implementing the functionality of certain embodiments may be stored by file storage subsystem526in the storage subsystem524, or in other machines accessible by the processor(s)514.

Bus subsystem512provides a mechanism for letting the various components and subsystems of the controller500communicate with each other as intended. Although bus subsystem512is shown schematically as a single bus, alternative embodiments of the bus subsystem may use multiple buses.

The controller500can be of varying types. Due to the ever-changing nature of computing devices and networks, the description of the controller500depicted inFIG.5is intended only as a specific example for purposes of illustrating some embodiments. Many other configurations of a controller are possible, having more or fewer components than the controller500depicted inFIG.5.

While the disclosed embodiments have been illustrated and described in considerable detail, it is not the intention to restrict or in any way limit the scope of the appended claims to such detail. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the various aspects of the subject matter. Therefore, the disclosure is not limited to the specific details or illustrative examples shown and described. Thus, this disclosure is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims, which satisfy the statutory subject matter requirements of 35 U.S.C. § 101. The above description of specific embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as defined by the appended claims, and equivalents thereof.