Welding power supply and user interface for a welding power supply

Abstract

The disclosed example power supplies, user interfaces, and methods provide for simple and intuitive setting of configurable and / or default settings for a welding power supply and / or wire feeder. Welding parameters may correspond to default and / or factory settings that represent empirically cited values for a particular welding process (e.g., based on material type, electrode diameter, welding process, and / or tool, etc.). The welding parameters may additionally or alternatively be configured for a specific purpose. Once a configurable setting is selected, the configurable setting controls the system output. Additionally, once a set of configurable welding parameters has been established, an operator may return to the default settings by resetting the welding parameters.

Description

[0001] Cross - Reference to Related Applications

[0002] This application is a non - provisional patent application that claims priority to U.S. Provisional Patent Application No. 62 / 897,778, filed on September 9, 2019, entitled "Welding Power Supplies And User Interfaces For Welding Power Supplies", the content of which is incorporated herein by reference in its entirety. Background Art

[0003] Conventional metal welding techniques utilize the heat generated by the arc effect to transform the workpiece into a molten state to facilitate the welding process. One technique that employs this arc effect principle is wire - feed welding. If the welding device is properly adjusted, the wire - feed advancement and arc - effect cycles will proceed smoothly, thus providing a good weld seam.

[0004] Traditionally, during a welding operation, the operator selects the level and type of resources provided to the welding location, which, of course, depends on the specific circumstances of the welding and the materials being welded. However, different types of wire electrodes perform well under different operating settings of the welding device.

[0005] Conventionally, welding devices rely on the operator's knowledge and ingenuity to select the most suitable voltage and wire - feed settings for the wire electrode being used and the welding conditions. Unfortunately, in many cases, welding operators are new to the industry, especially in the case of portable welding devices. If the operator does not properly adjust the voltage and wire - feed speed settings, the arc effect may be insufficient to produce a good weld seam or may not produce any weld seam at all. Additionally, in traditional devices, the wire - feed speed control and voltage control are either independent of each other or directly related, making it difficult for the operator to adjust the welding parameters to achieve a desired set of parameters. Summary of the Invention

[0006] Welding power supplies and user interfaces for welding power supplies are disclosed, substantially as shown in at least one of the figures and described in conjunction with at least one of the figures. Brief Description of the Drawings

[0007] These and other features, aspects, and advantages of the present disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like reference numerals represent like parts throughout all the figures:

[0008] Figure 1ASchematic diagram of an example welding system in accordance with aspects of the present disclosure, the example welding system including a power supply having a user interface for configuring a welding process.

[0009] Figure 1B Schematic diagram of another example welding system in accordance with aspects of the present disclosure, the another example welding system including a wire feeder having a user interface for configuring a welding process.

[0010] Figure 1C Schematic diagram of another example welding system in accordance with aspects of the present disclosure, the another example welding system including a user interface connected to a welding power supply and / or a wire feeder for configuring a welding process.

[0011] Figure 2 Front view of an example interface of a welding process including auto-set welding parameters in accordance with aspects of the present disclosure.

[0012] Figures 3 to 7 A series of representative example interfaces for implementing a configurable welding process in accordance with aspects of the present disclosure are provided.

[0013] Figures 8 to 10 A series of representative example interfaces for implementing a default welding process in accordance with aspects of the present disclosure are provided.

[0014] Figure 11 Another front view of an example interface of a welding process including auto-set welding parameters in accordance with aspects of the present disclosure.

[0015] Figure 12A and Figure 12B A flowchart of representative example machine-readable instructions in accordance with aspects of the present disclosure that may be executed by an example system of Figures 1A to 1C to implement a welding process including auto-set welding parameters.

[0016] The figures are not necessarily drawn to scale. Like or identical reference numerals are used to denote like or identical components where appropriate. Detailed Description

[0017] The disclosed example power supplies, user interfaces, and methods allow for simple and intuitive setup of configurable and / or default settings of a welding power source and / or a wire feeder.

[0018] In some examples, a welding system includes a power source for delivering power to a torch based on one or more welding parameters (e.g., voltage, current, power, wire feed speed, gas flow rate, pulse rate, workpiece thickness, workpiece material type, electrode type, welding process, travel speed, arc length, or joint type, etc.). As disclosed herein, the welding parameters can correspond to default settings and / or factory settings, which represent empirically cited values for a particular welding process (e.g., based on material type, electrode diameter, welding process, and / or tool, etc.). The welding parameters can be configured for a specific purpose. In other words, an interface (such as an auto-set button) can be provided to allow an operator to be able to adjust one or more welding parameters. A second input device (such as a selector switch, knob, touchscreen input) receives input from the operator related to a desired change in the value of one or more welding parameters. Once a configurable setting is selected, the configurable setting controls the system output without additional input. After a set of controlled welding parameters is established, the controller controls the power source to deliver power or controls a wire feeder to advance the electrode wire based on the preferred welding parameter settings of the control.

[0019] In addition, once a set of configurable welding parameters is established, the operator can return to the default settings by resetting the welding parameters. For example, the operator can provide an input corresponding to the selection to return to the default welding parameter settings, such as by using an auto-set button. The controller can then access the default welding parameter settings from a list of values associated with one or more default welding parameters (e.g., corresponding to best practices, empirically obtained values, etc.). After a successful reset, based on the default welding parameter settings, the power source delivers power or the wire feeder advances the electrode wire.

[0020] The status of the welding parameters (e.g., whether the setting corresponds to a default setting or a configured setting) and the values of the parameters can be displayed on a display device presented to the operator. For example, the display can include an information bar to display graphics or text corresponding to instructions or responses to the operator to assist in adjusting the welding parameter settings.

[0021] In the disclosed example, a welding system includes: a power source configured to deliver power to a torch based on one or more welding parameters; a wire feeder configured to advance a wire electrode to the torch based on the one or more welding parameters; and an interface. The interface includes: a first input device configured to receive an input corresponding to a selection of a default setting or a configurable setting for the one or more welding parameters; a display device configured to display a default indicator in response to selecting the default setting, or display a configurable indicator in response to selecting the configurable setting; and a second input device configured to receive an input related to a change in the value of the one or more welding parameters. Control circuitry is included and configured to: receive from the first input device an input corresponding to a selection of the configurable setting; receive from the second input device an input corresponding to a change in the value of a welding parameter among the one or more welding parameters; adjust the value of the welding parameter from the default welding parameter value of the one or more welding parameters based on the received change; assign the adjusted value as a preferred welding parameter setting and store the adjusted value in a list of values associated with one or more preferred welding parameters; control the power source to deliver power or control the wire feeder to advance the electrode wire based on the preferred welding parameter setting; receive from the first input device an input corresponding to a selection of the default welding parameter setting; access the default welding parameter setting from a list of values associated with one or more default welding parameters; and control the power source to deliver power or control the wire feeder to advance the electrode wire based on the default welding parameter setting.

[0022] In some examples, the control circuitry applies one or more adjustment boundaries such that adjustment of the default welding parameter value is limited by the one or more adjustment boundaries. In an example, the one or more adjustment boundaries are five percent of the default welding parameter value. In some examples, the one or more adjustment boundaries correspond to a predetermined value.

[0023] In an example, the interface includes a graphical range indicator to represent a default welding parameter range or a welding parameter threshold range such that an upper limit value is represented on a first side of the default welding parameter range and a lower limit value is represented on a second side of the default welding parameter range opposite the first side.

[0024] In some examples, the interface includes a graphical crosshair indicating selection of the default welding parameter. In an example, the interface includes a graphical band indicating selection of the configurable welding parameter. In some examples, a position of the graphical band on the graphical range indicator corresponds to a value of the welding parameter relative to the default welding parameter. In an example, the input type is one of a click, a double - click, or holding the input device for a predetermined amount of time, and the input type corresponds to different functions of the respective device.

[0025] In some examples, the control circuit system is further configured to control the power supply to deliver power according to one or more welding processes, and each of the one or more welding processes corresponds to one or more configurable settings. In an example, the one or more welding parameters include one or more of voltage, current, power, wire feed speed, gas flow rate, pulse rate, workpiece thickness, workpiece material type, electrode type, welding process, travel speed, arc length, or joint type.

[0026] In the disclosed examples, a welding system includes: a power supply configured to deliver power to a torch based on one or more welding parameters; a wire feeder configured to advance a wire electrode to the torch based on the one or more welding parameters, wherein the one or more welding parameters include voltage or wire feed speed; and an interface. The interface includes: a first input device configured to receive an input corresponding to a selection of a default setting or a configurable setting of the one or more welding parameters; a display device configured to display a default indicator in response to selecting the default setting, or display a configurable indicator in response to selecting the configurable setting. A voltage selection knob receives an input related to the voltage provided to the torch, and a wire feed speed selection knob receives an input related to the wire feed speed from the wire feeder. The control circuit system receives an input corresponding to a selection of a configurable setting from the first input device; receives an input corresponding to a change in one or more values of the voltage or the wire feed speed; adjusts the value of the voltage or the wire feed speed based on the received change; assigns the adjusted value of the voltage or the wire feed speed as a preferred welding parameter setting and stores the adjusted value in a list of values associated with one or more preferred welding parameters; and controls the power supply to deliver power or controls the wire feeder to advance the electrode wire based on the preferred welding parameter setting.

[0027] In some examples, the control circuit system receives an input corresponding to a selection of a default welding parameter setting from the first input device; accesses the default welding parameter setting from a list of values associated with one or more default welding parameters; and controls the power supply to deliver power or controls the wire feeder to advance the electrode wire based on the default welding parameter setting.

[0028] In some examples, an information bar is used to display a graphic or text to an operator, and the graphic or text provides instructions or responses corresponding to user input. In an example, the interface includes a welding process type input device configured to receive an input related to a welding process type, wherein a value of power output and a range of default welding parameter values are calculated at least in part based on the welding process type.

[0029] In some examples, the welding process type input device includes an option of one or more welding processes among metal inert gas (MIG) or tungsten inert gas (TIG) welding processes as the welding process type. In an example, the interface includes a workpiece input device configured to receive an input related to the material thickness of the workpiece, wherein the control circuitry is further configured to determine the default welding parameter values based on the material thickness.

[0030] In some examples, the interface includes a first graphical range indicator with an indication of the current value of the voltage and a second graphical range indicator with an indication of the current value of the wire feed speed. In an example, the control circuitry is further configured to update the indication of the current value of the voltage parameter in response to an input received via the voltage input device, and to update the indication of the current value of the wire feed speed in response to an input received via the wire feed speed input device.

[0031] In some examples, the control circuitry is further configured to apply one or more adjustment boundaries such that adjustments to the default welding parameter values are limited by the one or more adjustment boundaries.

[0032] As used herein, "power conversion circuitry" and / or "power conversion circuit" refers to a circuit system and / or electrical component that converts electrical power from one or more first forms (e.g., electrical power output by a generator) into one or more second forms having any combination of voltage, current, frequency, and / or response characteristics. The power conversion circuitry may include a safety circuitry, an output selection circuitry, a measurement and / or control circuitry, and / or any other circuitry for providing appropriate characteristics.

[0033] As used herein, the terms "first" and "second" may be used to enumerate different components or elements of the same type and do not necessarily imply any particular order.

[0034] As used herein, the term "welding-type system" includes any device capable of supplying electrical power suitable for welding, plasma cutting, induction heating, CAC-A, and / or hot wire welding / preheating (including laser welding and laser cladding), the device including an inverter, a converter, a chopper, a resonant power supply, a quasi-resonant power supply, etc., and an associated control circuitry and other auxiliary circuitry.

[0035] As used herein, the term "welding-type power" refers to power suitable for welding, plasma cutting, induction heating, CAC-A, and / or hot wire welding / preheating (including laser welding and laser cladding). As used herein, the term "welding power supply" and / or "power supply" refers to any device that can supply power for welding, plasma cutting, induction heating, CAC-A, and / or hot wire welding / preheating (including laser welding and laser cladding) when power is applied thereto, including but not limited to inverters, converters, resonant power supplies, quasi-resonant power supplies, etc., as well as associated control circuitry and other auxiliary circuitry.

[0036] As used herein, "circuit" or "circuitry" includes any analog and / or digital components, power and / or control elements (such as microprocessors, digital signal processors (DSPs), software, etc.), discrete components, and / or integrated components, or portions and / or combinations thereof.

[0037] The terms "control circuit", "control circuitry", and / or "controller" as used herein may include digital and / or analog circuitry, discrete and / or integrated circuitry, microprocessors, digital signal processors (DSPs), and / or other logic circuitry, and / or associated software, hardware, and / or firmware. The control circuit or control circuitry may be located on one or more circuit boards that form part or all of the controller and are used to control the welding process, devices such as power supplies or wire feeders, and / or any other type of welding-related system.

[0038] As used herein, the term "memory" includes volatile and non-volatile memory devices and / or other storage devices.

[0039] As used herein, the term "torch", "welding torch", welding tool, or "welding-type tool" refers to a device configured to be manipulated to perform welding-related tasks and may include a hand-held torch, robotic torch, welding gun, or other device for generating a welding arc.

[0040] As used herein, the terms "welding mode", "welding process", "welding-type process", or "welding operation" refer to the type of process or output used, such as constant current (CC), constant voltage (CV), pulsed, gas metal arc welding (GMAW), flux-cored arc welding (FCAW), gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), spraying, short circuiting, and / or any other type of welding process.

[0041] As used herein, the term "welding procedure" includes at least one set of welding parameters for controlling a weld. A welding procedure can further include other software, algorithms, processes, or other logic for controlling one or more welding-type devices to perform a weld.

[0042] Turning now to the drawings, Figure 1A is a block diagram of an example welding system 100 having a welding power supply 102, a wire feeder 104, and a torch 106. The welding system 100 powers, controls, and supplies consumables to a welding application to provide a simple and intuitive setting of configurable and / or default settings of the power supply 102 and / or the wire feeder 104. In other words, an interface (such as an auto-set button) can be provided to allow an operator to adjust one or more welding parameters. A second input device (such as a selector switch, a knob, a touchscreen input) receives input from the operator related to a desired change in the value of one or more welding parameters to establish configurable settings for controlling the system output without additional input. Additionally, once a set of configurable welding parameters has been established, the operator can return to the default settings by resetting the welding parameters.

[0043] In some examples, the power supply 102 supplies input power directly to the torch 106. Based on the desired welding application, the torch 106 can be configured for shielded metal arc welding (SMAW, or stick welding), tungsten inert gas (TIG) welding, gas metal arc welding (GMAW), flux-cored arc welding (FCAW). In the example shown, the power supply 102 is configured to supply power to the wire feeder 104, and the wire feeder 104 can be configured to transmit the input power to the torch 106. In addition to supplying input power, the wire feeder 104 can also supply filler metal to the torch 106 for various welding applications (e.g., GMAW welding, flux-cored arc welding (FCAW)). Although Figure 1A the example welding system 100 includes a wire feeder 104 (e.g., for GMAW or FCAW welding), the wire feeder 104 can be replaced by any other type of remote attachment device, such as a stick welding and / or TIG welding remote control interface providing stick welding and / or TIG welding.

[0044] The power supply 102 receives main power 108 (e.g., from an AC power grid, an engine / generator set, a battery, or other energy generation or storage devices, or a combination thereof), regulates the main power, and provides output power to one or more welding devices according to the requirements of the welding system 100. The main power 108 can be supplied from a remote location (e.g., the main power can be sourced from the power grid). The power supply 102 includes a power conversion circuitry 110, which can include a transformer, a rectifier, switches, etc., that are capable of converting the AC input power into AC and / or DC output power as specified by the requirements of the welding system 100 (e.g., specific welding processes and scenarios). The power conversion circuitry 110 converts the input power (e.g., the main power 108) into welding-type power based on a welding voltage setpoint and outputs the welding-type power via a welding circuit.

[0045] In some examples, the power conversion circuitry 110 is configured to convert the main power 108 into both a welding-type power output and an auxiliary power output. However, in other examples, the power conversion circuitry 110 is adapted to convert the main power only into a welding power output and provides a separate auxiliary converter 111 to convert the main power into auxiliary power. In some other examples, the power supply 102 directly receives the converted auxiliary power output from a wall socket. The power supply 102 can employ any suitable power conversion system or mechanism to generate and supply welding power and auxiliary power.

[0046] The power supply 102 includes a control circuitry 112 that controls the operation of the power supply 102. The power supply 102 further includes a user interface 114. The control circuitry 112 receives inputs from the user interface 114 through which a user can select a process and / or enter desired parameters (e.g., voltage, current, specific pulsed or non-pulsed welding scenarios, etc.). The user interface 114 can use one or more input devices 115 to receive inputs, such as via a keypad, keyboard, physical buttons, touch screen (e.g., software buttons), voice activation system, wireless device, etc. Additionally, the control circuitry 112 controls the operating parameters based on the user inputs and based on other current operating parameters. Specifically, the user interface 114 can include a display 116 that is used to present, show, or indicate information to an operator. The control circuitry 112 can also include an interface circuitry that is used to transfer data to other devices in the welding system 100, such as the wire feeder 104. For example, in some cases, the power supply 102 communicates wirelessly with other welding devices within the welding system 100. Additionally, in some cases, the power supply 102 communicates with other welding devices using a wired connection, such as by using a network interface controller (NIC) to transfer data via a network (e.g., Ethernet, 10baseT, 10base100, etc.). In Figure 1A an example, the control circuitry 112 communicates with the wire feeder 104 via a communication transceiver 118 via a welding circuit, as described below.

[0047] The control circuitry 112 includes at least one controller or processor 120 that controls the operation of the power supply 102. The control circuitry 112 receives and processes a plurality of inputs associated with the performance and requirements of the welding system 100. The processor 120 can include one or more microprocessors, such as one or more “general-purpose” microprocessors, one or more dedicated microprocessors, and / or ASICs, and / or any other type of processing device. For example, the processor 120 can include one or more digital signal processors (DSPs).

[0048] An example control circuitry 112 includes one or more storage devices 123 and one or more memories 124. The (multiple) storage devices 123 (e.g., non-volatile storage devices) can include ROM, flash memory, hard disk drive, and / or any other suitable optical storage medium, magnetic storage medium, and / or solid-state storage medium, and / or combinations thereof. The storage devices 123 store data (e.g., data corresponding to welding applications), instructions (e.g., software or firmware for performing welding processes), and / or any other suitable data. Examples of stored data for welding applications include the posture (e.g., orientation) of the torch, the distance between the contact tip and the workpiece, voltage, current, welding device settings, etc.

[0049] The memory 124 may include volatile memory, such as random access memory (RAM), and / or non-volatile memory, such as read only memory (ROM). The memory 124 and / or the storage device(s) 123 may store various information and may be used for various purposes. For example, the memory 124 and / or the storage device(s) 123 may store processor-executable instructions 125 (e.g., firmware or software) for execution by the processor 120. Additionally, one or more control schemes for various welding processes, along with associated settings and parameters, may be stored in the storage device 123 and / or the memory 124 together with code configured to provide a specific output during operation (e.g., start wire feeding, allow gas flow, capture welding current data, detect short circuit parameters, determine spatter amount). One or more lists or look-up tables may be provided, and / or a network connection to various databases available for informing decision making may be provided to access preferred welding parameters, store updated welding parameter settings, etc.

[0050] In some examples, welding power flows from the power conversion circuitry 110 to the wire feeder 104 and the torch 106 via the welding cable 126. An example welding cable 126 may be attached to and detached from welding studs at each of the power supply 102 and the wire feeder 104 (e.g., to facilitate replacement of the welding cable 126 in the event of wear or damage). Additionally, in some examples, welding data is provided via the welding cable 126 such that welding power and welding data are provided and transmitted together via the welding cable 126. The communication transceiver 118 is communicatively coupled to the welding cable 126 to transmit (e.g., send / receive) data via the welding cable 126. The communication transceiver 118 may be implemented using serial communication (e.g., full-duplex RS-232 or RS-422, or half-duplex RS-485), network communication (e.g., Ethernet, PROFIBUS, IEEE 802.1X wireless communication, etc.), parallel communication, and / or any other type of communication technology. In some examples, the communication transceiver 118 may implement communication via the welding cable 126.

[0051] An example communication transceiver 118 includes a receiver circuit 121 and a transmitter circuit 122. Generally, the receiver circuit 121 receives data transmitted by the wire feeder 104 via the welding cable 126, and the transmitter circuit 122 transmits data to the wire feeder 104 via the welding cable 126. The communication transceiver 118 is capable of remotely configuring the power supply 102 from the location of the wire feeder 104, and / or commanding and / or controlling the wire feed speed output by the wire feeder 104 and / or the welding power (e.g., voltage, current) output by the power supply 102.

[0052] The example wire feeder 104 also includes a communication transceiver 119, which can be similar or identical to the communication transceiver 118 in structure and / or function. Although communication through a separate communication cable is shown in Figure 1A , other communication media such as wireless media, power line communication, and / or any other communication media can also be used.

[0053] In some examples, the gas supplier 128 provides a shielding gas, such as argon, helium, carbon dioxide, etc., according to the welding application. The shielding gas flows to a valve 130, which controls the flow of the gas, and if necessary, this valve can be selected to allow adjustment or regulation of the amount of gas supplied to the welding application. The valve 130 can be opened, closed, or otherwise operated by the control circuitry 112 to allow, prohibit, or control the flow of gas (e.g., shielding gas) through the valve 130. The shielding gas exits the valve 130 and flows through a cable 132 (which can be combined with the welding power output in some embodiments) to the wire feeder 104, thereby providing a shielding gas for the welding application. In some examples, the welding system 100 does not include the gas supplier 128, the valve 130, and / or the cable 132.

[0054] In some examples, the wire feeder 104 uses welding power to power various components in the wire feeder 104, such as powering the wire feeder controller 134. As described above, the welding cable 126 can be configured to provide or supply welding power. The power supply 102 can also communicate with the communication transceiver 119 of the wire feeder 104 using the welding cable 126 and a cable communication transceiver 118 disposed within the power supply 102. In some examples, the communication transceiver 119 is substantially similar to the communication transceiver 118 of the power supply 102. The wire feeder controller 134 controls the operation of the wire feeder 104. In some examples, the wire feeder 104 uses the wire feeder controller 134 to detect whether the wire feeder 104 is communicating with the power supply 102, and if the wire feeder 104 is communicating with the power supply 102, to detect the current welding process of the power supply 102.

[0055] The contactor 135 (e.g., a high amperage relay) is controlled by the wire feeder controller 134 and is configured to allow or prohibit welding power from continuing to flow to the welding cable 126 for a welding application. In some examples, the contactor 135 is an electromechanical device. However, the contactor 135 can be any other suitable device, such as a solid state device. The wire feeder 104 includes a wire drive 136 that receives a control signal from the wire feeder controller 134 to drive a roller 138 that rotates to pull the welding wire away from the wire spool 140. The welding wire is provided to the welding application through the torch cable 142. Similarly, the wire feeder 104 can provide shielding gas from the gas supply 128 through the cable 142. The electrode wire, shielding gas, and power from the welding cable 126 are combined together in a single torch cable 144 and / or are provided separately to the welding torch 106. In some examples, the contactor 135 is omitted and the power is started and stopped by the power supply 102. In some examples, one or more sensors 127 are included in or coupled to the wire feeder 104 to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to inform the wire feeder controller 134 during the welding process. In some examples, one or more sensors are included in the welding power supply 102.

[0056] The torch 106 delivers the welding wire, welding power, and / or shielding gas for the welding application. The torch 106 is used to establish a welding arc between the torch 106 and the workpiece 146. The work cable 148 couples the workpiece 146 to the power supply 102 (e.g., to the power conversion circuitry 110) to provide a return path for the welding current (e.g., as part of the welding circuit). An example work cable 148 can be attached to and / or detached from the power supply 102 to facilitate replacement of the work cable 148. The work cable 148 can be terminated with a clamp 150 (or another electrical connection device) that couples the power supply 102 to the workpiece 146. In some examples, one or more sensors 147 are included in or coupled to the torch 106 to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to inform the wire feeder controller 134 and / or the control circuitry 112 during the welding process.

[0057] Figure 1B is a schematic diagram of another example welding system 152, where in addition to or as an alternative to the user interface on the welding power supply 102, the wire feeder 104 also includes a user interface 114. In Figure 1B example, the controller 134 of the wire feeder 104 implements the determination of the welding procedures and welding parameters described in the control circuitry 112 of reference Figure 1A

[0058] ​Figure 1C FIG. is a schematic view of another exemplary welding system 154 that includes a separate user interface 156. The user interface 156 is a separate device and can be connected to the welding power supply 102 and / or the wire feeder 104 to provide commands and / or control information. Exemplary user interface 156 includes an input device 115 and a display 116, and includes control circuitry 158. Exemplary control circuitry 158 includes one or more processors 120 and a memory 124 that stores instructions 125. Exemplary user interface 156 further includes a communication transceiver 119 that is used to enable communication between the user interface 156 and the welding power supply 102 and / or the wire feeder.

[0059] Although Figures 1A to 1C shown as having user interfaces (114, 156) incorporated with specific systems, the illustration is exemplary, and thus one or more of the interfaces disclosed herein and additional user interfaces can be incorporated in one or more of the exemplary welding systems disclosed herein. Additionally, although the power supply 102 and the wire feeder 104 are shown as separate units, in some examples, the power supply and the wire feeder can be housed in a single enclosure or otherwise integrated together. Additionally or alternatively, in some examples, a single controller, control circuitry, and / or interface can control the operation of both the power supply and the wire feeder.

[0060] Figure 2 An exemplary user interface 114 for implementing the adjustable auto-setup process disclosed herein is shown. In some examples, the welding systems 100, 152, 154 can implement a cooperative mode (once default or custom settings have been established), in which the control circuitry 112, the wire feeder controller 134, and / or the controller 158 determine a voltage value in response to a wire feed speed selected via the welding parameter adjustment dial 52 and a predetermined relationship between the wire feed speed and the voltage. In some examples, the predetermined relationship is selected based on a welding program or one or more welding parameters including workpiece type, workpiece thickness, etc. The control circuitry / controller can enable or disable the cooperative mode based on the selected welding program (e.g., based on selection of a cooperative welding process or a non-cooperative welding process).

[0061] When the control circuitry / controller implements the cooperative mode, the control circuitry / controller can determine a recommended workpiece or material thickness for the currently selected wire feed speed and / or welding program. For example, for a particular welding program and wire feed speed, a range of wire feed speeds can be suitably stored as a list of values associated with one or more welding parameters (e.g., voltage, current, workpiece characteristics) in one or more storage devices 123 and / or the memory 124.

[0062] Figure 2The exemplary user interface 114 is configured to coordinately adjust the voltage and wire feed speed operations based on the selected wire feed speed, such that the control circuitry / controller determines a corresponding voltage associated with one or more of the welding program, and / or welding process parameters, workpiece attributes, wire type parameters, wire size parameters, or gas type parameters based at least on the relationship between the wire feed speed and the voltage, all of which relationships may be stored, for example, as a list of values or a look-up table (e.g., in the (multiple) storage devices 123, memory 124, etc.). The control circuitry / circuit sets the voltage value determined based on this relationship.

[0063] As Figures 2 to 11 shown, the user interface 114 includes a welding process selector 40, an electrode diameter adjuster 42, a material thickness adjuster 44, an auto-set selector 46, a color display screen 48 (e.g., incorporated with the display 116, supplementary to the display 116, or alternative to the display 116) and welding parameter (e.g., voltage, wire feed speed, and / or amperage) adjustment dials 50 and 52. Reference is made to Figures 2 to 11 for components of the user interface 114 and / or 156, but Figures 2 to 11 may include the same and / or different components, features, characteristics, attributes, etc.

[0064] As Figure 2 shown, the welding process selector 40 may allow an operator or other user to select from multiple welding processes. For example, the welding process selector 40 allows an operator to select from welding processes such as stick welding process, flux-cored welding process, one or more metal inert gas (MIG) welding processes, one or more tungsten inert gas (TIG) welding processes, etc. In addition to the general welding processes, in some examples, the welding process selector 40 allows an operator to select the material of the welding electrode. For example, to implement a MIG welding process, an operator may select, for example, stainless steel, another type of steel, or an aluminum electrode to implement the MIG process. In some examples, the welding process selector 40 allows an operator to select a desired welding process (e.g., stick welding process, MIG welding process, TIG welding process, etc.), an electrode material type (e.g., steel, aluminum, etc.), and a gas type (e.g., C25, C100, argon, etc.), and then select to enable the auto-set function of the (multiple) welding systems 100, 152, 154 to automatically synchronize the appropriate voltage and wire feed speed and / or amperage welding parameters.

[0065] As in Figure 2As shown in the example of, the user interface 114 includes an electrode diameter adjuster 42 (e.g., an electrode wire, an electrode rod, or a tungsten electrode, depending on the type of welding process selected). The electrode diameter is an optional welding parameter for performing welding because the appropriate amperage of the welding arc depends on the diameter of the electrode wire. In some examples, the electrode diameter adjuster 42 has features such as a "+" button for increasing the electrode diameter setting and a "-" button for decreasing the electrode diameter setting. Similarly, the user interface 114 may also include a material thickness adjuster 44. For example, the material thickness adjuster includes a "+" button for increasing the material thickness setting (e.g., related to the workpiece 146 on which welding is to be performed) and a "-" button for decreasing the material thickness setting. The electrode diameter setting and the material thickness setting jointly affect the voltage and amperage (e.g., current) used to perform a given welding process.

[0066] In some examples, an operator or other user can select an automatic setting function via an automatic setting selector 46. When the automatic setting feature is enabled (e.g., activated by the operator), the operator can input the corresponding electrode diameter setting and material thickness setting of the power supply 102 to automatically adjust (e.g., increase or decrease) the desired welding parameters (such as voltage, wire feed speed, and / or amperage parameter) to appropriate settings.

[0067] In Figure 2 the example of, the automatic setting selector 46 is a on / off switch or a on / off button that can be activated or deactivated, allowing the operator to enable or disable the automatic setting function of the welding system 10. In the example, the user interface 114 includes one or more light indicators 54 (e.g., LEDs in some examples) to indicate whether the automatic setting function is enabled or disabled. For example, during the execution of a MIG welding process, the operator can select the automatic setting function via the automatic setting selector 46, and one or more light indicators 54 can display, for example, a blue light or other indication of the enabled automatic setting function to the operator. In some examples, the welding process selector 40 can be associated with a plurality of light indicators 55, each light indicator 55 being spatially aligned with a label corresponding to a respective welding process (e.g., "flux core", "MIG stainless steel", etc.), such that manipulation of the welding process selector 40 changes the selected welding process, and the light indicator 55 corresponding to the selected welding process can display, for example, a blue light or other indication of the specific welding process that has been selected, while the other light indicators 55 corresponding to other welding processes do not emit light.

[0068] Regarding the electrode diameter adjuster 42, material thickness adjuster 44, and auto-set selector 46, the user interface 114 includes a color display 48. The color display 48 can be any display device capable of displaying visual graphic objects and / or alphanumeric text related to the setting of welding parameters, the real-time operating status of the welding systems 100, 152, 154, etc. The information bar 64 can provide instructions or alerts associated with the selected welding parameters, welding processes, and / or changes to such parameters or processes. In Figure 2 an example, the color display 48 can be capable of displaying the selected electrode diameter (e.g.,.030"), material thickness (e.g., 1 / 8"), power supply welding voltage (e.g., 18.0 volts), and wire feed speed (e.g., 310 inches per minute).

[0069] In some examples, the welding process selector 40, electrode diameter adjuster 42, material thickness adjuster 44, auto-set selector 46, welding parameter adjustment dials 50 and 52, or any combination thereof can be displayed as graphical input devices on the color display 48. For example, the color display 48 can be a touch screen configured to receive input from the user via these graphical input devices displayed on the color display 48. For example, in certain examples, instead of (or in addition to) the actual physical input devices arranged on the user interface 114, other types of user input elements such as graphical buttons, sliders, knobs, etc. displayed via the color display 48 can be used to receive input from the user.

[0070] In the disclosed examples, when the auto-set selector 46 is enabled, the color display 48 can automatically display an acceptable range of values for the welding voltage and wire feed speed and / or amperage based on the input of the electrode diameter and / or material thickness parameters employed (e.g., these inputs can be set based on the manipulation of the electrode diameter adjuster 42 and / or material thickness adjuster 44). As used herein, an acceptable range of welding parameter values can be a range of values within which the power supply 102 maintains the voltage and wire feed speed and / or amperage in response to the values of the input or estimated electrode diameter and material thickness parameters such that welding can be effectively performed. For example, as Figure 2As shown, a welding operator can input an electrode diameter of.030” and a material thickness of 1 / 8” via the user interface 114. In response to the input, the power supply 102 can automatically set 18.0 volts and 310 inches per minute as appropriate welding parameter settings to perform welding for these specific electrode diameter and material thickness characteristics. The welding parameters can then be displayed via the color display screen 48. The user interface 114 also includes welding parameter adjustment dials 50 and 52, which can be used to manually adjust (e.g., increase or decrease) the voltage and wire feed speed parameters and / or the amperage parameter within a desired value range according to the specific type of welding process selected using the welding process selector 40.

[0071] In some examples, when the automatic setting selector 46 is enabled, if there are current values of the voltage and wire feed speed parameters and / or the amperage parameter, these values can be automatically adjusted to bring them within their respective acceptable value ranges. For example, if the current wire feed speed value is higher than the acceptable value range of the wire feed speed determined by the control circuitry 112 when the automatic setting selector 46 is selected (e.g., activated), the wire feed speed can be automatically adjusted by the control circuitry 112 to reduce the wire feed speed to a value just within the acceptable value range of the wire feed speed, to a value just within a preferred sub-range of the acceptable value range of the wire feed speed (e.g., a second acceptable value range within the acceptable value range), or to the desired value of the wire feed speed within the acceptable value range. Similar adjustments can also be made to the current and / or voltage to bring lower values up to certain ranges or values.

[0072] In some examples, when the (multiple) welding systems 100, 152, 154 are powered on, a message can be automatically displayed via the information bar 64 to prompt the operator to enable the automatic setting function via the automatic setting selector 46. In the case where the operator selects the automatic setting function by activating the automatic setting selector 46, one or more messages can subsequently prompt the operator to select one or both of the electrode diameter setting and the material thickness setting via the electrode diameter adjuster 42 and the material thickness adjuster 44, respectively. Similarly, in the case where the operator changes or switches the welding process via, for example, the welding process selector 40, a message can be automatically displayed via the information bar 64. These messages can be displayed to present further instructions to the operator to perform the selected welding process.

[0073] In some examples, the text of such a message can be displayed on the information bar 64 in a font that is larger than the usual font, in a text color that is different from the usual text color (e.g., white text on a black background, or black text on a white background), and / or associated with a colored graphic (e.g., a red exclamation point, etc.), so as to better attract the user's attention. These features can provide supplementary guidance related to appropriate welding settings (e.g., related to the shielding gas to be used, the polarity to be used, etc.) to the operator or user of the (multiple) welding systems 100, 152, 154, and thus ensure that the welding is carried out correctly.

[0074] In an example, the automatic setting function of the welding system 10 is enabled or disabled via the automatic setting selector 46 of the user interface 114. When the automatic setting is enabled, the power supply 102 can automatically set the welding voltage, welding amperage, and wire feed speed for a variety of welding processes, electrode material types, and shielding gas types. When the automatic setting is disabled, the power supply 102 can determine the acceptable value ranges for the welding voltage, welding amperage, and wire feed speed, thereby allowing the operator to manually adjust the parameters within the acceptable value ranges. For illustrative purposes, the automatic setting function is described with respect to MIG and / or flux-cored welding processes, stick welding processes, and TIG welding processes, as Figures 2 to 11 depicted.

[0075] In an example, the automatic setting selector 46 of the user interface 114 can be enabled to automatically set the welding voltage and wire feed speed parameters for MIG or flux-cored welding processes. In the MIG welding process, appropriate settings of the welding voltage and wire feed speed parameters are presented to the operator, because the welding voltage generally determines the height and width of the weld bead, and the amperage of the welding arc generally depends on the wire feed speed. With the automatic setting selector 46 enabled, the operator can then select the electrode diameter and material thickness via the electrode diameter adjuster 42 and the material thickness adjuster 44, respectively. The welding power supply 102 can then automatically determine the acceptable voltage and wire feed speed parameters. For example, as Figure 2 depicted within the color display screen 48 showing the MIG standby state, ".030" represents the input value of the electrode diameter, "1 / 8" represents the input value of the material thickness, and 18.0 volts and 310 inches per minute respectively represent the acceptable value ranges automatically determined for the welding voltage and wire feed speed parameters.

[0076] In some examples, as Figure 2 shown, the color display screen 48 can display a plurality of discrete electrode diameter setting indicators 56 (e.g., a segmented line along a range of potentially selectable electrode diameter settings is shown as a set of discrete points), wherein, with respect to the currently selected electrode diameter setting (e.g., as Figure 2The discrete electrode diameter setting indicators 56 corresponding to the indicated.030”) are highlighted, for example, by being displayed in a relatively bright color (e.g., bright blue in some examples), while all other discrete electrode diameter setting indicators 56 are displayed in a relatively neutral color (e.g., gray in some examples). Thus, when the user selects an electrode diameter via the electrode diameter adjuster 42, the appropriate discrete electrode diameter setting indicator 56 is selected. The plurality of discrete electrode diameter setting indicators 56 are intended to assist the user in understanding where the currently selected electrode diameter setting lies within the range of potentially selectable electrode diameter settings. As described herein, the number of discrete electrode diameter setting indicators 56 displayed by the color display 48 is determined based on other settings input by the user. For example, in some examples, based on all other settings input via the user interface 114, the color display 48 will display only the discrete electrode diameter setting indicators 56 corresponding to the electrode diameter settings that are reasonable based on these other input settings.

[0077] Similarly, as Figure 2 shown, the color display 48 may display a plurality of discrete material thickness setting indicators 58 (e.g., a segmented line along a range of potentially selectable material thickness settings is displayed as a set of discrete points), where the discrete material thickness setting indicator 58 corresponding to the currently selected material thickness setting (e.g., 1 / 8” as Figure 2 shown) is highlighted, for example, by being displayed in a relatively bright color (e.g., bright blue in some examples), while all other discrete material thickness setting indicators 58 are displayed in a relatively neutral color (e.g., gray in some examples). Thus, when the user selects a material thickness via the material thickness adjuster 44, the appropriate discrete material thickness setting indicator 58 is selected. The plurality of discrete material thickness setting indicators 58 are intended to assist the user in understanding where the currently selected material thickness setting lies within the range of potentially selectable material thickness settings. As described herein, the number of discrete material thickness setting indicators 58 displayed by the color display 48 is determined based on other settings input by the user. For example, in some examples, based on all other settings input via the user interface 114, the color display 48 will display only the discrete material thickness setting indicators 58 corresponding to the material thickness settings that are reasonable based on these other input settings.

[0078] In Figure 2In the example, the color display screen 48 displays the graphical range indicators 60 and 62 to depict (e.g., display changing colors and / or movement of range bars) whether the welding voltage and / or wire feed speed parameters are within an acceptable value range when the operator adjusts one or both of the welding parameter adjustment dials 50 and 52. Thus, when the operator makes an adjustment via one (or both) of the welding parameter adjustment dials 50 and 52, the graphical range indicators 60 and 62 (respectively related to the parameters adjusted by the welding parameter adjustment dials 50 and 52) on the color display screen 48 depict the acceptable value ranges of their respective welding parameters (e.g., voltage and wire feed speed in the example shown in Figure 2 ).

[0079] In some examples, each graphical range indicator 60, 62 shows a default welding parameter range or a welding parameter threshold range corresponding to the plateau portion of the trapezoidal indicator. In other words, the upper limit value is represented on the first side (e.g., the right side) of each welding parameter range. The lower limit value is represented on the second side (e.g., the left side) opposite the first side of each welding parameter range.

[0080] Generally, when one of the welding parameter adjustment dials 50 and 52 is manipulated (e.g., adjusting the welding parameter adjustment dial 52 related to the wire feed speed in Figure 2 ), the acceptable value range of the relevant welding parameter (e.g., the wire feed speed in Figure 2 ) is shown on the color display screen 48. In some examples, a graphical band or slider bar may be provided to indicate where the current welding parameter value is within the acceptable range (e.g., the slider bar 78 of the graphical range indicator 62 shown in Figure 11 ). Additionally, in the example, the welding parameter adjustment dials 50 and 52 may be configured to accept values that fall within the acceptable value ranges of the welding parameters. For example, when a manual adjustment attempted via the welding parameter adjustment dials 50 and 52 would cause their respective parameters to reach values outside their respective acceptable value ranges (represented as one or more boundaries beyond which the values may not go), such a manual adjustment may be blocked by the control circuitry 112. Thus, an attempt to adjust the value beyond the limit will not be reflected in the parameters on the color display screen 48. Further, in certain examples, after receiving an input via the welding parameter adjustment dials 50 and 52, the graphical range indicators 60 and 62 may display on the color display screen 48 for only a predetermined (e.g., pre-set according to the settings of the welding systems 100, 152, 154) amount of time (e.g., 15 seconds, 10 seconds, 5 seconds, 3 seconds, or some other predetermined amount of time).

[0081] Conversely, when the automatic setting selector 46 is disabled, the operator can manually adjust (e.g., increase or decrease) the welding voltage and wire feed speed parameters within the acceptable value range within the margins (e.g., by manipulating the welding parameter adjustment dials 50 and 52, which correspond to the parameters displayed directly above the respective welding parameter adjustment dials 50 and 52 on the color display screen 48). In this way, depending on which of the welding parameter adjustment dials 50 and 52 are manipulated, either of the graphical range indicators 60 and 62 can include a crosshair 72 or 74 and / or a slider (e.g., Figure 11 slider 78) within their respective acceptable range graphics.

[0082] As described herein, in some examples, the crosshairs 72, 74 and / or the slider 78 can be displayed in varying colors to assist the user in determining how to adjust the welding parameter adjustment dials 50 and 52. For example, in certain examples, the crosshairs 72, 74 can be displayed in a specific color (e.g., blue in some examples), and the slider 78 can be displayed in a color different from that of the crosshairs 72, 74, such that the user can easily distinguish between the two cases. Additionally, it should be noted that in certain examples, the acceptable range graphic can include three different segments. For example, the middle segment of the acceptable range graphic can correspond to a "preferred" subset (e.g., sub-range) of the acceptable value range (e.g., at the plateau of the trapezoidal indicator), as determined by the control circuitry 112, while the two slanted side segments of the acceptable range graphic (e.g., to the left and right of the plateau) can correspond to values that are still within the acceptable value range but are not preferred values.

[0083] As shown in the figures, Figures 2 to 7 a series of representative example interfaces for implementing a configurable welding process are provided. For example, Figure 2 shows the display at the start of the welding process. From Figure 2 the display provided, the operator will press and hold the automatic setting selector 46. As Figure 3 shown, the crosshairs 72 and 74 are removed from the color display screen 48, indicating that the welding process is no longer operating at the default welding parameters. The information bar 64 provides an instruction to release the automatic setting selector 46. Once released, as Figure 4 shown, the information bar 64 instructs the operator to perform one of the following actions: click the automatic setting selector 46 (to save the adjusted one or more welding parameters) or hold the automatic setting selector 46 for a predetermined amount of time (e.g., one second or more; to return the welding parameters to the default or factory settings).

[0084] As Figure 5As shown, the operator has, for example, adjusted the wire feed speed from 310 inches per minute to 385 inches per minute via the welding parameter adjustment turntables 52. After reaching the desired welding parameter settings (385 IPM), the operator clicks the Auto Set selector 46 to Figure 6 prompt the message bar 64 to indicate that the new settings have been saved. As Figure 6 shown, once the new settings are saved, the crosshairs 72, 74 reappear on the graphical range indicators 60, 62 to indicate that the currently displayed welding parameter settings (e.g., 18.0 volts, 385 IPM wire feed speed) are set values that can be co-related.

[0085] Thus, Figure 7 a user interface 114 during a welding operation is shown, where, except for the adjusted wire feed speed representing a configurable setting, the displayed indicators are similar to Figure 2 . There may be a time lag (e.g., one second or more), an instruction to confirm the adjustment, and / or other mechanisms to ensure and / or indicate acceptance of the adjusted welding parameter settings. In some examples, once accepted, the configurable welding parameter settings are controlled such that the operator should take additional actions to reverse the process (return to the default welding parameter settings) and / or further adjust the welding parameters. For example, the operator can repeat the actions regarding Figures 2 to 7 provided to further adjust one or more welding parameters, such as to further adjust the wire feed speed. In some examples, once the desired settings are saved, the operator can further adjust the welding parameters, such as via the welding parameter adjustment turntables 50 and 52.

[0086] In some examples, the range of values that the operator can select is, for example, limited by the control circuitry. For example, once a value is selected from the default welding parameter settings or a custom value, the control circuitry assigns boundaries that the selection device will not allow the welding parameter value to increase or decrease beyond. In some examples, these adjustment boundaries can correspond to a certain percentage of the selected welding parameter value (e.g., 1% - 10% of the parameter value). In some examples, one or more adjustment boundaries correspond to a predetermined value (e.g., + / - 5 volts; + / - 30 IPM; etc.).

[0087] In the case where the operator wishes to return the welding parameter settings to the default values, the process can be reversed as provided in reference to Figures 8 to 10 . From Figure 7 , the operator presses and holds the Auto Set selector 46. As Figure 8As shown, the information bar 64 provides instructions to release the button (such as after a predetermined amount of time), and the crosshairs 72, 74 on the graphical range indicators 60, 62 are removed from the color display 48. Once the auto-set selector 46 is released, the information bar 64 instructs the operator to click the button to save the settings, or hold the button to force a reset to the default welding parameter settings, as Figure 9 shown. In Figure 10 the example of, the operator holds the auto-set selector 46 for a predetermined amount of time (such as one second or more), which returns the wire feed speed to 310 IPM. As Figure 10 shown, the crosshairs 72, 74 reappear, indicating that the settings have returned to the default welding parameter settings.

[0088] In Figure 10 , the color display 48 returns to a default display setting similar to those provided in Figure 2 , including a thermal indicator 66 representing the temperature of the welding systems 100, 152, 154 during a welding operation. Additionally or alternatively, the thermal indicator 66 can be displayed with varying characteristics, such as changing color to indicate relative changes in temperature (e.g., blue indicates cold or decreasing temperature, while red indicates high temperature or increasing temperature). In some examples, the thermal indicator can provide an indication of the temperature of various components and / or the environment. In an example, the displayed indicator can be selected by the operator.

[0089] Although one or more example input types have been disclosed using some examples herein, these and other types of input can be employed to implement the provided actions. For example, the input can be one or more of the following actions: click, double-click, or hold the input device for a predetermined amount of time. In some examples, the input type corresponds to different functions of the respective device or welding parameter.

[0090] In Figure 11 the example shown, when the slider 78 is within the middle segment of the acceptable value range, the slider 78 can be displayed in a first color (e.g., green in some examples), while when the slider 78 is within the side segment of the acceptable value range, the slider 78 can be displayed in a second color (e.g., yellow in some examples) to indicate that the currently selected value is no longer within the preferred subset of the acceptable value range but is still within the acceptable value range. Although Figure 11 the example shows a slider 78 associated with the wire feed speed on the graphical range indicator 62, in some examples, one or more sliders can be displayed on each graphical range indicator 60, 62 to show variable or adjustable values of the associated welding parameters.

[0091] In addition, in some examples, when the slider 78 reaches the outer boundary of the acceptable value range (e.g., the downward slope of the trapezoidal graphical range indicators 60, 62), the slider 78 can be displayed in a third color (e.g., red in some examples) to indicate that the currently selected value is no longer within the acceptable value range. In other examples, the color of the slider 78 can vary based on the magnitude of the current value of the corresponding parameter. For example, if the current amperage value is at the lower end of its acceptable value range, the color of the corresponding slider 78 can be blue, and if the current amperage value is at the upper end of its acceptable value range, the color of the corresponding slider 78 can be red, and as the amperage value changes from the lower end to the upper end, the color of the corresponding slider 78 can gradually transition between blue and red. Such examples are intended to convey a relative amount of heat input into a welding application.

[0092] Additionally or alternatively, one or more program indicators and / or selectors can be provided on the user interfaces 114, 156. In this example, once a welding parameter setting or an addition to a welding parameter setting has been saved, the operator can assign it to a memory (e.g., a saved configuration corresponding to the first saved welding setting, the second saved welding setting, etc.). In this way, if a desired welding setting has been achieved (e.g., for a particular welding process, tool, type, etc.), the operator can save that particular setting and return to it when needed.

[0093] Figure 12A and Figure 12B A flowchart depicting example machine-readable instructions 200 is provided, which can be executed by Figure 1A example welding system 100, Figure 1B example welding system 152, and / or Figure 1C example welding system 154 to configure one or more graphical user interfaces during a welding process. Example instructions 200 can be stored in the storage device(s) 123 and / or memory 124 and executed by the processor(s) 120 of the control circuitry 112. Example instructions 200 are described below with reference to the example graphical user interfaces of FIGS. 1 through Figure 11 . As provided in the flowchart, Figure 12A the blocks 202 through 218 provided in Figure 12B represent establishing configurable settings, while

[0094] In block 202, an input is received via a first input device, the input corresponding to a selection of a default setting or a configurable setting of one or more welding parameters. In block 204, the control circuitry determines whether the selection corresponds to a default setting or a configurable setting of one or more welding parameters. In block 206, an input corresponding to a selection of a configurable setting is received at the control circuitry (e.g., control circuitry 112) from the first input device (e.g., auto-set selector 46). In block 208, the display device displays a configurable indicator in response to the selection of the configurable setting.

[0095] In block 210, an input corresponding to a change in the value of a particular one of one or more welding parameters is received at the control circuitry from a second input device (e.g., welding parameter adjustment dials 50, 52). In block 212, the control circuitry adjusts the value of the welding parameter starting from the default welding parameter value of one or more welding parameters based on the received change. In block 214, the control circuitry assigns the adjusted value as the preferred welding parameter setting. In block 216, the adjusted value is stored in a list of values associated with one or more preferred welding parameters (e.g., stored in storage device(s) 123 and / or memory 124). In block 218, the control circuitry controls the power supply to deliver power or controls the wire feeder to advance the electrode wire based on the preferred welding parameter setting.

[0096] In block 220, an input corresponding to a selection of a default setting or a configurable setting of one or more welding parameters is received at the first input device. In block 222, the control circuitry determines whether the selection corresponds to a default setting or a configurable setting of one or more welding parameters. In block 224, an input corresponding to a selection of a default welding parameter setting is received at the control circuitry from the first input device. In block 226, the display device (e.g., color display screen 48) displays a default indicator (e.g., crosshairs 72, 74) in response to the selection of the default setting. In block 228, the control circuitry accesses the default welding parameters from a list of values associated with one or more default welding parameters (e.g., in storage device(s) 123 and / or memory 124). In block 230, the control circuitry controls the power supply to deliver power or controls the wire feeder to advance the electrode wire based on the default welding parameter setting.

[0097] The present apparatus and / or method can be implemented using hardware, software, or a combination of hardware and software. The method and / or system can be implemented in a centralized manner in at least one computing system, processor, and / or other logic circuits, or in a distributed manner with different elements spread across several interconnected computing systems, processors, and / or other logic circuits. Any kind of computing system or other device suitable for executing the methods described herein is suitable. A typical combination of hardware and software can be a processing system integrated in a welded power supply with a program or other code that, when loaded and executed, controls the welded power supply so that it implements the methods described herein. Another typical implementation can include application-specific integrated circuits or chips, such as field-programmable gate arrays (FPGAs), programmable logic devices (PLDs), or complex programmable logic devices (CPLDs) and / or systems-on-chip (SoCs). Some embodiments can include non-transitory machine-readable (e.g., computer-readable) media (e.g., flash memories, optical discs, magnetic storage disks, etc.) having one or more lines of code executable by a machine stored thereon, whereby the machine performs the processes described herein. As used herein, the term "non-transitory machine-readable medium" is defined to include all types of machine-readable storage media and does not include propagated signals.

[0098] The control circuitry can identify the welding condition of a given weld and automatically find the optimal value of the current rise rate for the welding condition. Example control circuit implementations can be an Atmel Mega16 microcontroller, an STM32F407 microcontroller, a field-programmable logic circuit, and / or any other control or logic circuit capable of executing instructions to run welding control software. The control circuit can also be implemented as a combination of analog circuits and / or digital circuit systems and analog circuit systems. These examples are described herein with reference to engine-driven stick welders, but these examples can be used or modified for use in any type of high-frequency switching power supply.

[0099] Although the method and / or system have been described with reference to certain embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted without departing from the scope of the method and / or system. Additionally, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope of the disclosure. For example, the blocks and / or components of the disclosed examples can be combined, divided, rearranged, and / or otherwise modified. Thus, the method and / or system are not limited to the particular embodiments disclosed. Instead, the method and / or system will include all embodiments that fall within the scope of the appended claims, literally or under the doctrine of equivalents.

Claims

1. A welding system, comprising: A power source configured to deliver electrical power to a torch based on one or more welding parameters; A wire feeder configured to advance an electrode wire to the torch based on the one or more welding parameters; An interface, the interface comprising: A first input device configured to receive an input corresponding to a selection of a default setting or a configurable setting for the one or more welding parameters; A display device configured to display a default indicator in response to a selection of the default setting or a configurable indicator in response to a selection of the configurable setting; and A second input device configured to receive an input related to a change in the value of the one or more welding parameters; and A control circuitry configured to: Receive an input from the first input device corresponding to a selection of the configurable setting; Enable the second input device to receive an input in response to a selection of the configurable setting; Display the configurable indicator on the interface corresponding to a selection of the configurable setting; Receive an input from the second input device corresponding to a change in the value of a certain welding parameter among the one or more welding parameters; Adjust the value of the welding parameter starting from the default welding parameter value of the one or more welding parameters based on the received change; Assign the adjusted value as a preferred welding parameter setting and store the adjusted value in a list of values associated with one or more preferred welding parameters; Control the power source to deliver electrical power or control the wire feeder to advance the electrode wire based on the preferred welding parameter setting; After controlling the power source to deliver electrical power or controlling the wire feeder to advance the electrode wire based on the preferred welding parameter setting, receive an input from the first input device corresponding to a selection of the default welding parameter setting; Disable the second input device from receiving an input in response to a selection of the default welding parameter setting; Display the default indicator on the interface corresponding to a selection of the default welding parameter setting; Access the default welding parameter setting from a list of values associated with one or more default welding parameters; and Control the power source to deliver electrical power or control the wire feeder to advance the electrode wire based on the default welding parameter setting.

2. The welding system according to claim 1, wherein, The control circuitry is further configured to apply one or more adjustment boundaries such that the adjustment of the default welding parameter value is limited by the one or more adjustment boundaries.

3. The welding system according to claim 2, wherein, The one or more adjustment boundaries are five percent of the default welding parameter value.

4. The welding system according to claim 2, wherein, The one or more adjustment boundaries correspond to a predetermined value.

5. The welding system according to claim 1, wherein, The interface further includes a graphical range indicator to represent a default welding parameter range or a welding parameter threshold range such that an upper limit value is represented on a first side of the default welding parameter range and a lower limit value is represented on a second side of the default welding parameter range opposite to the first side.

6. The welding system according to claim 1, wherein, The default indicator includes a graphical crosshair indicating that default welding parameters are selected.

7. The welding system according to claim 5, wherein, The configurable indicator includes a graphical strip indicating that configurable welding parameters are selected.

8. The welding system according to claim 7, wherein, The position of the graphical strip on the graphical range indicator corresponds to the value of the configurable welding parameter relative to the default welding parameter range.

9. The welding system according to claim 1, wherein, The input type is one of the following actions: clicking, double - clicking, or holding the input device for a predetermined amount of time, and the input type corresponds to different functions of the corresponding device.

10. The welding system according to claim 1, wherein, The control circuitry is further configured to control the power supply to deliver power according to one or more welding processes, and each of the one or more welding processes corresponds to one or more configurable settings.

11. The welding system according to claim 1, wherein, The one or more welding parameters include one or more of voltage, current, power, wire feed speed, gas flow rate, pulse rate, workpiece thickness, workpiece material type, electrode type, welding process, travel speed, arc length, or joint type.

12. A welding system, comprising: A power supply configured to deliver power to a torch based on one or more welding parameters; A wire feeder configured to advance an electrode wire to the torch based on the one or more welding parameters, wherein the one or more welding parameters include voltage or wire feed speed; An interface, the interface comprising: A first input device configured to receive an input corresponding to the selection of a default setting and an input corresponding to a configurable setting for the one or more welding parameters; A display device configured to display a default indicator in response to the selection of a default setting and a configurable indicator in response to the selection of a configurable setting; A voltage selection knob configured to receive an input related to the voltage provided to the torch; A wire feed speed selection knob configured to receive an input from the wire feeder related to the wire feed speed; and A control circuitry configured to: Receive an input from the first input device corresponding to the selection of a configurable setting; Enable the control circuitry to receive an input from the voltage selection knob or the wire feed speed selection knob in response to the selection of the configurable setting; Receive an input from the voltage selection knob or the wire feed speed selection knob corresponding to a change in one or more values of the voltage or the wire feed speed; Adjust the value of the voltage or the wire feed speed based on the received change; Assign the adjusted value of the voltage or the wire feed speed as a preferred welding parameter setting and store the adjusted value in a list of values associated with one or more preferred welding parameters; and Control the power supply to deliver power or control the wire feeder to advance the electrode wire based on the preferred welding parameter setting.

13. The welding system according to claim 12, wherein, The control circuitry is further configured to: Receive an input from the first input device corresponding to the selection of a default welding parameter setting; Disable the control circuitry from receiving input from the voltage selection knob or the wire feed speed selection knob in response to selection of the default welding parameter settings; Access the default welding parameter settings from a list of values associated with one or more default welding parameters; And Control the power supply to deliver power or control the wire feeder to advance the electrode wire based on the default welding parameter settings.

14. The welding system according to claim 12, wherein, Further include an information bar for displaying graphics or text to the operator, the graphics or text providing instructions or responses corresponding to user input.

15. The welding system according to claim 12, wherein, The interface further includes a welding process type input device configured to receive input related to a welding process type, wherein a range of values of the power output and a range of default welding parameter values are calculated at least in part based on the welding process type.

16. The welding system according to claim 15, wherein, The welding process type input device includes selectable options including one or more welding processes such as metal inert gas (MIG) or tungsten inert gas (TIG) welding processes as welding process types.

17. The welding system according to claim 12, wherein, The interface includes a workpiece input device configured to receive input related to the material thickness of the workpiece, wherein the control circuitry is further configured to determine default welding parameter values based on the material thickness.

18. The welding system according to claim 12, wherein, The interface further includes a first graphical range indicator with an indication of the current value of the voltage and a second graphical range indicator with an indication of the current value of the wire feed speed.

19. The welding system according to claim 18, wherein, The control circuitry is further configured to update the indication of the current value of the voltage parameter in response to input received via the voltage selection knob and to update the indication of the current value of the wire feed speed in response to input received via the wire feed speed selection knob.

20. The welding system according to claim 12, wherein, The control circuitry is further configured to apply one or more adjustment boundaries such that adjustment of the default welding parameter values is limited by the one or more adjustment boundaries.

21. A welding system, comprising: A power supply configured to deliver power to a torch based on one or more welding parameters; A wire feeder configured to advance an electrode wire to the torch based on the one or more welding parameters; An interface, the interface including: A first input device configured to receive input corresponding to selection of a default setting or a configurable setting for the one or more welding parameters; A display device configured to display a default indicator in response to selection of the default setting or a configurable indicator in response to selection of the configurable setting; and A second input device configured to receive input related to a change in the value of the one or more welding parameters; A third input device configured to receive one or more adjustment boundaries associated with a corresponding one of the one or more welding parameters in response to selection of the default setting or selection of the configurable setting; and A control circuit system, the control circuit system being configured to: Receive an input from the first input device, the input corresponding to a selectable configurable setting; Receive an input from the second input device, the input corresponding to a change in the value of a certain welding parameter among the one or more welding parameters; Adjust the value of the welding parameter starting from the default welding parameter value of the one or more welding parameters based on the received change; Assign the adjusted value as a preferred welding parameter setting and store the adjusted value in a list of values associated with one or more preferred welding parameters; Control the power supply to deliver power or control the wire feeder to advance the electrode wire based on the preferred welding parameter setting; Receive an input from the first input device, the input corresponding to a selection of a default welding parameter setting; Access the default welding parameter setting from a list of values associated with one or more default welding parameters; and Control the power supply to deliver power or control the wire feeder to advance the electrode wire based on the default welding parameter setting.

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