System and method for automatic control of welding parameter output range

Abstract

The disclosed example power supplies, user interfaces, and methods are provided for intuitive or automatic control of welding parameter output ranges. The disclosed systems and methods provide tools for setting configurable settings and / or default settings of a welding power source and / or wire feeder. The welding settings include upper and lower limits on an operating range corresponding to one or more welding parameters, such that the welding parameter values are bounded by the upper and lower limits during a welding operation. In some examples, the operating range and corresponding upper and lower limits are calculated or determined based on a selected range tolerance.

Description

[0001] Cross-references to related applications

[0002] This application is a non-provisional patent application that claims priority to U.S. Provisional Patent Application No. 62 / 909,516, filed October 2, 2019, entitled “Systems and Methods For Automatic Control Of Welding Parameter Output Ranges,” the contents of which are incorporated herein by reference in their entirety. Background Technology

[0003] Common metal welding techniques utilize the heat generated by an electric arc to molten the workpiece, facilitating the welding process. One technique employing this arc principle is wire-fed welding. With proper adjustment of the welding apparatus, wire feeding and arc cycles will proceed smoothly, resulting in a good weld.

[0004] Traditionally, during welding operations, the operator selects the level and type of resources provided to the welding position, depending on the details of the weld and the material being welded. However, different types of welding wire electrodes perform well under different operating settings of the welding apparatus.

[0005] Conventionally, welding apparatus relies on the operator's knowledge and skill to select the most suitable voltage level, wire feed settings, and other parameters for the welding wire electrode used in a specific welding condition. However, in many cases, the welding operator is a novice in the field. If the operator does not properly adjust the voltage and wire feed speed settings for each welding attempt, the arc may be insufficient to produce a good weld, or no weld may be produced at all. Furthermore, in conventional apparatuses, 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 the desired set of parameters. Summary of the Invention

[0006] The disclosed example power supply, user interface, and methods are provided for intuitive or automated control of the output range of welding parameters. The disclosed systems and methods provide tools for setting configurable and / or default settings for the welding power supply and / or wire feeder. Welding settings include upper and lower limits of the operating range corresponding to one or more welding parameters, such that the welding parameter values ​​are defined by these upper and lower limits during welding operations. In some examples, the operating range and the corresponding upper and lower limits are calculated or determined based on selected range tolerances. Attached Figure Description

[0007] These and other features, aspects, and advantages of the present disclosure will become better understood with reference to the following detailed description and appended claims, predictably drawn to illustrate specific embodiments thereof, wherein:

[0008] FIG. 1A is a schematic diagram of an example welding system including a power supply having a user interface for implementing automatic control of a welding parameter output range in accordance with aspects of the present disclosure.

[0009] FIG. 1B is a schematic diagram of another example welding system including a wire feeder having a user interface for implementing automatic control of a welding parameter output range in accordance with aspects of the present disclosure.

[0010] FIG. 1C is a schematic diagram of another example welding system including a user interface connected to a welding power supply and / or wire feeder to implement automatic control of a welding parameter output range in accordance with aspects of the present disclosure.

[0011] FIGS. 2A-2C An example selection tool for range tolerance selection for welding parameters of a welding process in accordance with aspects of the present disclosure is illustrated.

[0012] FIG. 3 An example graphical user interface displaying a welding parameter output range in accordance with aspects of the present disclosure is provided.

[0013] FIG. 4 A flowchart representing example machine-readable instructions that can be executed by an example system to implement range tolerance selection for welding parameters of a welding process in accordance with aspects of the present disclosure is provided. FIGS. 1A-1C

[0014] The drawings are not necessarily to scale. Like or similar designations in the various drawings indicate like or similar elements. DETAILED DESCRIPTION

[0015] The disclosed example power supplies, user interfaces, and methods provide intuitive tools for setting configurable and / or default settings of a welding power source and / or wire feeder. In some examples, these settings include upper and lower limits on an operating range corresponding to one or more welding parameters. These upper and lower limits are set such that any variation in the welding parameter value (e.g., output value) during a welding operation is bounded by the upper and lower limits.

[0016] ​In some examples, the operating range and corresponding upper and lower limits are calculated or determined based on a selected range tolerance. In other words, the input can indicate a tolerance associated with a particular range. The input can correspond to operator input and / or data associated with a particular welding procedure, welding tool, or welding process type. In some examples, one or more range tolerances are available for selection such that a tight range tolerance can be employed having calculated or determined upper and lower limits to provide relatively small variations from a selected welding parameter value. A wide range tolerance can be employed having upper and lower limits calculated or determined to allow relatively large variations from a selected welding parameter value. Additionally or alternatively, a standard (e.g., default) setting can be employed such that variations between the upper and lower limits fall between a tight tolerance and a wide tolerance (e.g., + / - 7% for voltage; + / - 10% for current).

[0017] Adjusting the range of welding parameters (and in particular, the range tolerance) in conventional systems is cumbersome, e.g., requiring each boundary value to be manually selected one-by-one. In some cases, boundaries will be automatically set for all applicable welding parameter ranges without any opportunity to customize the boundaries or ranges. Advantageously, the presently disclosed systems and methods provide an intuitive solution such that operating limits and boundaries can be readily calculated or determined for each welding parameter or two or more related welding parameters based on one or more factors (e.g., one or more range tolerance selections).

[0018] In some examples, the welding system includes a power source for delivering power to a welding tool 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 have values including a range having an operating upper limit and an operating lower limit corresponding to a default setting and / or factory setting. The welding parameter values and operating limit ranges can represent empirically observed and / or determined values for a particular welding parameter and / or welding procedure (e.g., based on material type, electrode diameter, welding process, and / or tool, etc.).

[0019] The welding parameters can be configured for a particular purpose. In other words, a welding program or sequence can provide a configuration value for one or more welding parameters to the control circuitry. In some examples, a range tolerance setting can be selected for each welding parameter such that the control circuit controls the system output based on the selected welding parameter value and / or the associated range tolerance. After establishing the control range tolerance for one or more applicable welding parameters, the control circuitry calculates or determines an upper limit and a lower limit for each welding parameter based on the control range of the applicable welding parameter, the control circuitry controls the power source to deliver power (or in certain welding operations, the control wire feeder to advance the electrode wire).

[0020] Furthermore, once the range tolerance has been set for one or more welding parameters, the settings can be returned to default settings (e.g., standard settings, factory settings, etc.) by resetting the range tolerance of one or more welding parameters. For example, an operator (e.g., a welding supervisor, an administrator, and / or a welder) can provide an input corresponding to a selection to return to default range tolerances for the welding parameters. For example, the controller can access default welding parameter range tolerance settings from a list of values (e.g., values corresponding to best practices, empirically obtained values, etc.) associated with one or more default welding parameter range tolerances. Upon successful reset, the power source delivers power (and / or the wire feeder advances the electrode wire) based on the default welding parameter range tolerances.

[0021] The selected particular range tolerance (e.g., is the range tolerance corresponding to a strict tolerance, a standard tolerance, or a lenient tolerance) and the value of the selected welding parameter can be displayed on a display device presented to the operator. For example, the display can include a color scheme indicating the particular range tolerance and / or information bars for displaying graphics or text to the operator corresponding to: the current output value, the selected range tolerance, and / or instructions or responses for assisting in adjusting the welding parameter value and / or the range tolerance.

[0022] In some examples, a unique range tolerance can be assigned for each applicable welding parameter such that even when one or more output values are adjusted during a welding operation, any calculated or determined range limits are consistent with the assigned range tolerance.

[0023] In the disclosed examples, a welding system includes control circuitry to control a power source based on a range of values associated with one or more welding parameters. The control circuitry receives a selected range tolerance from one or more range tolerances associated with the one or more welding parameters, calculates or determines an upper limit value and a lower limit value based on the selected range tolerance and a certain welding parameter of the one or more welding parameters, and controls the power source to deliver power based on the selected welding parameter.

[0024] In some examples, the one or more range tolerances include a tight range tolerance, a standard range tolerance, or a wide range tolerance. In some examples, the controller is further configured to adjust the range tolerance between a lower limit of the tight range tolerance and an upper limit of the wide range tolerance in response to the input.

[0025] In some examples, the input is a change in a certain one of the one or more welding parameters. In some examples, the input is an operator input from a user interface including one or more of a knob, a touch screen panel, or a dial.

[0026] In some examples, the tight range tolerance is narrower than the standard range tolerance, and the standard range tolerance is narrower than the wide range tolerance. In some examples, the control circuitry is further configured to calculate or determine the upper limit value and the lower limit value such that a predetermined value is added to or subtracted from the selected welding parameter value, respectively. In some examples, the predetermined value includes a first predetermined value and a second predetermined value, the first predetermined value is added to the selected value, and the second predetermined value is subtracted from the selected value, wherein the first predetermined value and the second predetermined value are different.

[0027] In some examples, the control circuitry is further configured to calculate or determine the upper limit value and the lower limit value by adding a first percentage of an absolute value of the selected welding parameter value to the selected welding parameter value or subtracting a second percentage of the absolute value of the selected welding parameter value from the selected welding parameter value.

[0028] In some examples, the one or more welding parameters further include a second welding parameter, the welding parameter selects a range tolerance from a first plurality of range tolerances of the one or more range tolerances, and the second welding parameter selects a second range tolerance from a second plurality of range tolerances of the one or more range tolerances, the second plurality of range tolerances being different from the first plurality of range tolerances.

[0029] In some examples, the one or more welding parameters include one or more of a voltage, a current, a power, a wire feed speed, a gas flow rate, a pulse rate, a workpiece thickness, a workpiece material type, an electrode type, a welding process, a travel speed, an arc length, or a joint type.

[0030] In disclosed examples, a welding system includes a power source configured to deliver power to a welding tool based on one or more welding parameters. A wire feeder is configured to advance a wire electrode to a welding torch based on the one or more welding parameters. And control circuitry controls the power source or the wire feeder based on a value range associated with the one or more welding parameters. The control circuitry receives a selection of a welding parameter value associated with a first welding parameter of the one or more welding parameters, receives a range tolerance selected from one or more range tolerances associated with the first welding parameter, calculates or determines an upper value and a lower value of the value range based on the selected range tolerance and the selected welding parameter value, and controls the power source to deliver power or controls the wire feeder to advance the electrode wire based on the value range and the selected welding parameter value.

[0031] In some examples, the control circuitry is further configured to designate the selected welding parameter value and the corresponding value range as a custom welding parameter setting, and store the selected welding parameter value and the corresponding value range in a list of values associated with one or more custom welding parameters.

[0032] In some examples, the control circuitry is further configured to: receive an input corresponding to the custom welding parameter setting; and control the power source to deliver power or control the wire feeder to advance the electrode wire based on the custom welding parameter setting.

[0033] In some examples, the control circuitry is further configured to: receive an input related to a welding process type; and calculate or determine a value range for one or more welding parameters based at least in part on range tolerances associated with the one or more welding parameters for the welding process type.

[0034] In some examples, the welding process type input device includes one or more welding processes of a gas metal arc welding (GMAW), a gas tungsten arc welding (GTAW), a plasma cutting, an air carbon arc cutting (CAC-A), or a shielded metal arc welding process as selectable options for the welding process type.

[0035] In some examples, the control circuitry is further configured to: receive an input corresponding to one or more default settings for the one or more welding parameters; access the default settings from a list of values associated with the one or more welding parameters; and control the power source to deliver power or control the wire feeder to advance the electrode wire based on the one or more default settings.

[0036] In some examples, the control circuitry is further configured to: receive a selection of a second welding parameter value associated with a second welding parameter of the one or more welding parameters; receive a second range tolerance selected from the one or more range tolerances associated with the second welding parameter; calculate or determine an upper value and a lower value of a second value range based on the selected range tolerance and the selected second welding parameter value; and control the power source to deliver power or the wire feeder to advance the electrode wire based on the second value range and the selected second welding parameter value.

[0037] In disclosed examples, a welding system includes a wire feeder configured to advance a wire electrode to a welding torch based on one or more welding parameters, and control circuitry to control the wire feeder based on a value range associated with the one or more welding parameters, the control circuitry configured to: receive a selection of a welding parameter value associated with a first welding parameter of the one or more welding parameters; receive a range tolerance selected from one or more range tolerances associated with the first welding parameter; calculate or determine an upper value and a lower value of the value range based on the selected range tolerance and the selected welding parameter value; and control the wire feeder to advance the electrode wire based on the value range and the selected welding parameter value.

[0038] In some examples, the control circuitry determines the upper value and the lower value by: accessing a list of welding parameter values corresponding to an upper value or a lower value; comparing the selected welding parameter value to the list of welding parameter values; and determining one or more of the upper value or the lower value based on the values in the list and the welding parameter value.

[0039] As used herein, “power conversion circuitry” and / or “power conversion circuit” refers to circuitry and / or electrical components that convert power from one or more first forms (e.g., power output by a generator) to one or more second forms having any combination of voltage, current, frequency, and / or response characteristics. Power conversion circuitry can include safety circuitry, output selection circuitry, measurement and / or control circuitry, and / or any other circuitry to provide appropriate features.

[0040] As used herein, the terms “first” and “second” can be used to enumerate different components or elements of the same type, and do not necessarily imply any particular order.

[0041] As used herein, the term "welding-type system" includes any device capable of supplying power suitable for welding, plasma cutting, induction heating, air carbon arc cutting (e.g., CAC-A), and / or hot wire welding / preheating (including laser welding and laser cladding), including inverters, converters, choppers, resonant power supplies, quasi-resonant power supplies, and the like, as well as control circuitry and other ancillary circuitry associated therewith.

[0042] 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 terms "welding-type power supply" and / or "power supply" refer to any device capable of supplying power to 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, and the like, as well as control circuitry and other ancillary circuitry associated therewith.

[0043] 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.

[0044] As used herein, the terms "control circuit," "control circuitry," and / or "controller" can include digital and / or analog circuitry, discrete and / or integrated circuitry, microprocessors, digital signal processors (DSPs), and / or other logic circuitry, and / or associated software, hardware, and / or firmware. Control circuitry or control circuitry can be located on one or more circuit boards that form part or all of a controller and are used to control a welding process, a device such as a power source or wire feeder, and / or any other type of welding-related system.

[0045] As used herein, the term "memory" includes volatile and non-volatile memory devices and / or other storage devices.

[0046] As used herein, the terms "torch," "welding torch," "welding tool," or "welding-type tool" refer to a device configured to be capable of manipulating for performing welding-related tasks and can include a handheld welding torch, a robotic welding torch, a welding gun, a gouging tool, a cutting tool, or other device for generating a welding arc.

[0047] 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 current control (CC), voltage control (CV), pulsed gas metal arc welding (GMAW), flux cored arc welding (FCAW), gas tungsten arc welding (GTAW, e.g., TIG), shielded metal arc welding (SMAW), spray transfer, short circuit, CAC-A, gouging processes, cutting processes, and / or any other type of welding process.

[0048] As used herein, the term "welding program" or "weld program" includes at least one set of welding parameters used to control a weld. The welding program can further include other software, algorithms, processes, or other logic used to control one or more welding-type devices to perform a weld.

[0049] Turning now to the drawings, FIG. 1A is a block diagram of an example welding system 100 having a welding-type power supply 102, a wire feeder 104, and a welding torch 106. The welding system 100 powers, controls, and supplies consumables to a welding application for intuitive setting of configurable settings and / or default settings of the power supply 102 and / or 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, knob, touchscreen input, receives input from the operator regarding a desired change in value of one or more welding parameters to establish a configurable setting for controlling system output without additional input. Further, once a set of configurable welding parameters has been established, the operator can return to the default settings by resetting the welding parameters.

[0050] In some examples, the power supply 102 directly supplies input power to the welding torch 106. Based on the desired welding application, the welding torch 106 can be a welding torch configured for shielded metal arc welding (SMAW, or stick welding), gas tungsten arc welding (GTAW or tungsten inert gas (TIG) welding), gas metal arc welding (GMAW), flux cored arc welding (FCAW). In the illustrated example, 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 welding torch 106. In addition to supplying input power, the wire feeder 104 can also supply filler metal to the welding torch 106 for various welding applications (e.g., GMAW welding, flux cored arc welding (FCAW)). Although FIG. 1AThe example system 100 includes a wire feeder 104 (e.g., for GMAW or FCAW welding), but the wire feeder 104 can be replaced by any other type of remote accessory, such as a stick welding and / or GTAW welding remote control interface that provides stick welding and / or GTAW welding.

[0051] The power supply 102 receives primary power 108 (e.g., from an AC power grid, an engine / generator set, a battery, or other energy generation or storage device, or a combination thereof), conditions the primary power, and provides output power to one or more welding devices according to the needs of the system 100. The primary power 108 can be supplied from an off-site location (e.g., the primary power can originate from a power grid). The power supply 102 includes power conversion circuitry 110, which can include transformers, rectifiers, switches, and the like, that are capable of converting AC input power to AC and / or DC output power as dictated by the needs of the system 100 (e.g., particular welding processes and regimes). The power conversion circuitry 110 converts input power (e.g., the primary power 108) to welding-type power based on a welding voltage setpoint and outputs the welding-type power via a welding circuit.

[0052] In some examples, the power conversion circuitry 110 is configured to convert the primary power 108 to 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 primary power to only a welding power output, and a separate auxiliary converter 111 is provided to convert the primary power to auxiliary power. In some other examples, the power supply 102 receives a converted auxiliary power output directly from a wall outlet. The power supply 102 can employ any suitable power conversion system or mechanism to generate and supply both welding power and auxiliary power.

[0053] The power supply 102 includes control circuitry 112 for controlling the operation of the power supply 102. The power supply 102 also includes a user interface 114. The control circuitry 112 receives input from the user interface 114 through which a user can select a process and / or input desired parameters (e.g., voltage, current, specific pulsed or non-pulsed welding regime, etc.). The user interface 114 can receive input using one or more input devices 115, such as via a keypad, keyboard, physical buttons, a touch screen (e.g., software buttons), a voice activation system, a wireless device, etc. Further, the control circuitry 112 controls operating parameters based on the user’s input as well as based on other current operating parameters. In particular, the user interface 114 can include a display 116 for presenting, showing, or indicating information to an operator. The control circuitry 112 can also include interface circuitry for communicating data to other devices in the 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. Further, 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 communicate data via a network (e.g., Ethernet, 10baseT, 10base100, etc.). In FIG. 1A In examples, the control circuitry 112 communicates with the wire feeder 104 via welding circuitry via a communication transceiver 118, as described below.

[0054] 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 number of inputs associated with the performance and requirements of the system 100. The processor 120 can include one or more microprocessors, such as one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and / or ASICS, and / or any other type of processing device. For example, the processor 120 can include one or more digital signal processors (DSPs).

[0055] In some examples, the control circuitry 112 is configured to implement the limit setting features disclosed herein. For example, the control circuitry 112 receives input associated with a certain range tolerance of one or more range tolerance options (e.g., from operator input and / or data associated with a particular welding program, tool, or type). Based on the input, the range calculation engine 129 of the control circuitry 112 calculates or determines an upper limit value and a lower limit value. In some examples, a welding parameter value is selected (e.g., from operator input and / or data associated with a particular welding program, tool, or type), and the range calculation engine 129 employs a selected range tolerance to calculate the upper limit value and the lower limit value. In some examples, a predetermined value (e.g., one integer) is calculated (e.g., based on a selected welding parameter type, welding parameter value, welding program, or combination of various factors), and then the predetermined value is added to or subtracted from the selected welding parameter value to produce the upper and lower limits, respectively. The control circuitry 112 then employs these upper and lower limits to control the power source to deliver power and / or control the wire feeder to advance an electrode wire based on the calculated upper and lower limits and the selected welding parameter value.

[0056] In some examples, the same predetermined value (e.g., the same number) is used to calculate the upper and lower limits. In some examples, a first predetermined value is added to the selected welding parameter value, and a different second predetermined value is subtracted from the selected welding parameter value. For example, the difference can be determined empirically, calculated by the control circuitry 112, commanded by user input or a welding program.

[0057] In some examples, the range calculation engine 129 calculates the upper limit value and the lower limit value by adding a certain percentage of the absolute value of the selected welding parameter value to the selected welding parameter value; and / or subtracting the same percentage (or a different percentage) of the absolute value of the selected welding parameter value from the selected welding parameter value.

[0058] A single selected range tolerance (e.g., strict, standard, wide) can be applied to each of one or more welding parameters. In some examples, different range tolerances can be assigned for different welding parameters. For example, a first welding parameter (e.g., voltage) can be assigned a first range tolerance (e.g., a standard range tolerance). A second welding parameter (e.g., wire feed speed) can be assigned a second range tolerance (e.g., a strict range tolerance). Thus, the calculated range for the respective welding parameter will vary by different amounts, and the control circuitry 112 will command the power source to output power according to the respective range tolerance. In some examples, a first welding parameter selects a range tolerance from a first plurality of range tolerances (e.g., - / + 5%, - / + 10%, - / + 15%) that is different from a second plurality of range tolerances (e.g., - / + 10%, - / + 20%, - / + 30%) available for a second welding parameter. As disclosed herein, the particular values / percentages / tolerances for each range tolerance and / or plurality of range tolerances can be provided by input.

[0059] In some examples, once one or more ranges have been calculated for a particular welding parameter(s), the range(s) can be designated as a custom setting. The custom setting can be associated with a particular welding operation, tool, welder, etc., and can be designated with an identifier for ease of lookup. The custom setting can then be stored in memory (e.g., in storage device(s) 123 and / or memory 124), which can be called via the interface 114 and / or displayed on the display 116 for viewing and selection.

[0060] In some examples, the control circuitry 112 accesses one or more lists or lookup tables that include list entries of welding parameter values corresponding to upper or lower limit values. For example, the control circuitry 112 (e.g., via the range calculation engine 129) compares the absolute value of the selected welding parameter value to the list entries of welding parameter values and determines one or more of the upper or lower limit values based on the values in the list and a certain range tolerance selected from one or more range tolerances. The values in the list (e.g., welding parameter values, upper limit values, lower limit values, etc.) can be customized (e.g., via the user interface 114, 156) and then stored in memory (e.g., in storage device(s) 123 and / or memory 124) for later access.

[0061] In some examples, the control circuitry 112 stores one or more welding program sequences, such as associated with a welding process type (e.g., metal inert gas (MIG) or gas tungsten arc welding (GTAW) welding process, plasma cutting, etc.), in the memory 124. As disclosed herein, each welding program sequence can contain one or more welding parameter values and associated ranges. In some examples, input such as from a user can indicate a desired range tolerance, and the range calculation engine 129 calculates upper and lower limits for each welding parameter value of the selected welding program sequence, as disclosed herein. The control circuitry 112 can access one or more welding program sequences in response to input (e.g., from a welding operation sequence and / or operator input). Input can be provided via the user interface 114 and / or from a remote controller via the network interface 117.

[0062] In some examples, the control circuitry 112 stores range tolerance settings for one or more welding parameters, such as in the memory 124. In response to input selecting a default setting, the ranges for the one or more welding parameters will return to the default settings. In some examples, custom settings can be adjusted using the processes disclosed herein, and / or can be deleted and removed from the memory 124 in response to input.

[0063] The example control circuitry 112 includes one or more storage devices 123 and one or more memory devices 124. The storage device(s) 123 (e.g., non-volatile storage) can include ROM, flash memory, a hard disk drive, and / or any other suitable optical, magnetic, and / or solid-state storage medium and / or a combination thereof. The storage device 123 stores data (e.g., data corresponding to a welding application), instructions (e.g., software or firmware for performing a welding process), and / or any other suitable data. Examples of stored data for a welding application include a pose (e.g., orientation) of a welding torch, a distance between a contact tip and a workpiece, a voltage, a current, a welding device setting, a deposition rate, a wire feed speed, a weld pool fluidity, etc.

[0064] The memory device 124 can include volatile memory, such as random access memory (RAM), and / or non-volatile memory, such as read-only memory (ROM). The memory device 124 and / or the storage device(s) 123 can store various information and can be used for various purposes. For example, the memory device 124 and / or the storage device(s) 123 can 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, can be stored in the storage device 123 and / or the memory device 124 along with code configured to provide particular outputs during operation (e.g., initiate wire feed, allow gas flow, capture welding-related data, detect short circuit parameters, determine spatter amount). One or more lists or lookup tables can be provided, and / or a network connection to various databases can be available for use to inform decisions to access preferred welding parameters, store updated welding parameter settings, etc.

[0065] In some examples, welding power flows from the power conversion circuitry 110 to the wire feeder 104 and the torch 106 through the welding cable 126. The example welding cable 126 can attach and detach 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). Further, in some examples, welding data is provided through the welding cable 126, such that welding power and welding data are provided and transmitted together through the welding cable 126. The communication transceiver 118 is communicatively coupled to the welding cable 126 to communicate (e.g., send / receive) data through the welding cable 126. The communication transceiver 118 can 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. IX wireless communication, etc.), parallel communication, and / or any other type of communication technology. In some examples, the communication transceiver 118 can implement communication through the welding cable 126.

[0066] The 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 allows the power supply 102 to be arranged in a location that is relatively distant from the wire feeder 104, and / or to command and / or control wire feed speed output by the wire feeder 104 and / or welding power (e.g., voltage, current) output by the power supply 102. In some examples, communication is transmitted via a dedicated cable between components and / or wireless communication channels, among other suitable communication devices and / or technologies.

[0067] The example wire feeder 104 also includes a communication transceiver 119, which can be similar or identical in structure and / or function to the communication transceiver 118. While communication over a separate communication cable is shown in FIG. 1A Other communication media can also be used, such as wireless media, power line communication, and / or any other communication media.

[0068] In some examples, the gas supply 128 provides 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 gas, and can be selected to allow adjustment or regulation of the amount of gas supplied to the welding application, if desired. The valve 130 can be opened, closed, or otherwise operated by the control circuitry 112 to enable, disable, 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, in some implementations, can be combined with the welding power output device) to the wire feeder 104, which provides the shielding gas to the welding application. In some examples, the welding system 100 does not include the gas supply 128, the valve 130, and / or the cable 132.

[0069] In some examples, the wire feeder 104 uses welding power to power various components in the wire feeder 104, such as to power a 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 the 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 in communication with the power supply 102 and, if the wire feeder 104 is in communication with the power supply 102, to detect the current welding process of the power supply 102.

[0070] In some examples, the power supply 102 delivers power output directly to the welding torch 106 without employing any contactors. In such examples, power regulation is controlled by the control circuitry 112 and / or the power conversion circuitry 110. In some examples, a contactor 135 (e.g., a high amperage relay) is employed and controlled by the wire feeder controller 134 and is configured to allow or inhibit the continuation of welding power to the welding cable 126 according to the 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 control signals from the wire feeder controller 134 to drive a roller 138 that rotates to pull welding wire off of a wire spool 140. The welding wire is provided to the welding application through a torch cable 142. Likewise, the wire feeder 104 can provide shielding gas from the cable 142 to the welding application. The electrode wire, shielding gas, and power from the welding cable 126 are combined together in a single torch cable 144 and / or provided separately to the welding torch 106. In some examples, the contactor 135 is omitted and the output or welding-type power is initiated and stopped by the power supply 102 without employing a contactor 135. In some examples, one or more sensors 127 are included in or connected with the wire feeder 102 to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to notify the controller 134 during the welding process. In some examples, one or more sensors are included in the welding power supply 102.

[0071] The torch 106 delivers welding wire, welding power, and / or shielding gas for welding applications. The torch 106 is used to establish a welding arc between the torch 106 and the workpiece 146. A work cable 148 couples the workpiece 146 to the power supply 102 (e.g., to the power conversion circuitry 110) to provide a return path for the welding current (e.g., as part of a welding circuit). The example work cable 148 can be attached 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 power connection device) that couples the power supply 102 to the workpiece 146. In some examples, one or more sensors 147 are included in or connected with the torch 106 to monitor one or more welding parameters (e.g., power, voltage, current, wire feed speed, etc.) to issue notifications to the controllers 134 and / or 112 during a welding process. Although the torch 106 (e.g., a welding tool as described herein) is shown as being connected to the welding power supply 102 through the wire feeder 104, in some examples, the welding tool can be connected directly to the welding power supply 102. For example, a gouging and / or cutting tool can be connected directly to a terminal post or another power outlet of the welding power supply 102. In some examples, the wire feeder is integrated with the power supply, and the terminal post or other power outlet is provided on the housing of this integrated containment.

[0072] FIG. 1B is a schematic diagram of another example welding system 152 in which the wire feeder 104 includes a user interface 114 in addition to or as an alternative to the user interface on the welding power supply 102. In this example, the control circuitry 134 of the wire feeder 104 implements the welding programs and determinations of welding parameters described with reference to the control circuitry 112 of the welding power supply 102. FIG. 1B FIG. 1A

[0073] FIG. 1C is a schematic diagram of another example 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. The example user interface 156 includes an input device 115 and a display 116 and includes control circuitry 158. The example control circuitry 158 includes a processor(s) 120 and a memory 124 storing instructions 125. The example user interface 156 further includes a communication transceiver 119 to allow communication between the user interface 156 and the welding power supply 102 and / or the wire feeder.

[0074] Although the user interface 156 is shown as being connected to the welding power supply 102 and / or the wire feeder 104, in some examples, the user interface 156 is connected to a separate welding tool (e.g., a torch, a gouging tool, a cutting tool, etc.) to provide commands and / or control information to the welding tool. FIGS. 1A-1C ​​The power supply 102 and wire feeder 104 are shown as separate units, but in some examples, the power supply and 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 operation of both the power supply and wire feeder.

[0075] FIGS. 2A-2C Example user interface elements for implementing the adjustable range tolerance settings disclosed herein are shown (e.g., selection tools that can be provided via the user interface 114). For example, a separate command to activate the range adjustment procedure can be provided, such as a switch, button, instruction, etc. (e.g., a “simple limit” button). As shown in the example, once activated, the knob or dial 164 can be turned around a number associated with a range of tolerance from a strict tolerance (e.g., at the lower end of the range) to a lenient tolerance (e.g., at the upper end of the range). The selected range tolerance can be displayed in the information screen 162. Although shown with a single value (e.g., a 60% range tolerance for the maximum allowable variation of the voltage output), the range tolerance selection can be toggled back and forth between various welding parameters or welding programs, such that different range tolerances can be specified for different welding parameters. FIG. 2A

[0076] FIG. 2B An example selection tool is shown with a first button 166 for scrolling and / or incrementing the value upward and a second button 168 for scrolling and / or decrementing the value downward. As shown, three range tolerances are provided for selection, such that the highlighted “lenient” range tolerance 170 is selected and the standard tolerance 172 and strict tolerance 174 are deselected. Similarly, the range tolerance selection can be toggled back and forth between various welding parameters or welding programs, such that different range tolerances can be specified for different welding parameters by employing the selection tool or other related input device. FIG. 2B

[0077] FIG. 2C ​​An example selection tool is shown displaying a plurality of sliders 182 with three graphical selectors for weld parameter value selector 186, upper limit selector 184, and lower limit selector 188. Shown near each slider 182 is the value corresponding to the respective selector 184, 186, 188. For example, display 190 shows that the upper limit for the weld parameter is set to 25 volts, the desired weld parameter value is set to 18 volts, and the lower limit is set to 5 volts. FIG. 2C Three weld parameter selection tools are provided in the example interface of FIG. 18, enabling simultaneous adjustment and / or observation of voltage 176, current 178, and wire feed speed 180. In some examples, more or more applicable weld parameters are provided and / or selectable from a list of weld parameters.

[0078] In some examples, the selection tools can be displayed as graphical input devices on the color display 116. For example, the color display 116 can be a touchscreen configured to receive input from a user via such graphical input devices displayed on the color display 116. For example, in certain examples, instead of (or in addition to) 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 116 can be used to receive input from a user. In some examples, FIG. 2C The selection tools of FIG. 18 can be used as a display associated with a separate input device (e.g., a remote control and / or physical selectors) to provide a visual indication of the selected weld parameters and associated limits.

[0079] In some examples, (once default settings or custom settings have been established) the weld system(s) 100, 152, 154 can implement a synergistic mode in which the control circuitry 112, controller 134, and / or controller 158 receives a selection of a first weld parameter value (e.g., via an interface and / or from a programmed weld sequence) and calculates a second weld parameter value based on a predetermined relationship between the first weld parameter and the second weld parameter. In some examples, the predetermined relationship corresponds to a selected weld sequence program or a user-confirmed relationship. The control circuitry / controller can enable or disable the synergistic mode based on the selected weld sequence program (e.g., based on whether a synergistic or non-synergistic welding process was selected).

[0080] When the control circuit system / controller implements a cooperative mode, the control circuit system / controller can determine recommended ranges and / or range tolerances for one or more applicable and / or selected welding parameters and / or welding procedures. For example, when suitable for a particular welding procedure and wire feed speed, the range tolerances and / or ranges of values ​​can be stored as a list of values ​​associated with one or more welding parameters (e.g., voltage, current, workpiece characteristics, etc.) in storage device(s) 123 and / or memory 124.

[0081] In some examples employing a collaborative mode, each of one or more welding parameters is subject to a single range tolerance selection. However, in other examples, the selection of one or more welding parameters can be deselected, and different range tolerances can be assigned to the welding parameters. For instance, if a custom welding procedure is being used, but the operator wants a particular welding parameter to have a different range tolerance, the operator can switch back and forth between applicable welding parameters, deselect the particular welding parameter, and use one or more selection tools to adjust the value and / or range tolerance associated with that particular welding parameter.

[0082] In some examples, an automatic range setting procedure can be enabled or activated, allowing the power supply 102 to automatically set the welding voltage, welding amperage, and wire feed speed for multiple welding processes, electrode material types, and shielding gas types. Therefore, the upper and lower limits for each welding parameter are calculated or determined based on the welding procedure or process and / or associated range tolerances. When automatic range setting is disabled, the power supply 102 can, for example, determine acceptable ranges for the welding voltage, welding amperage, and wire feed speed (e.g., standard or default value ranges and / or ranges calculated or determined based on default range tolerances), thereby allowing the operator to manually adjust the parameters within acceptable ranges.

[0083] FIG. 3 A sample graphical user interface 200 is shown, which can be used for implementation. FIGS. 1A-1C The (multiple) graphical user interfaces 114, 156 and / or displays 116. FIG. 3 The graphical user interface 200 includes one or more graphical interfaces 202 and 204, and one or more welding characteristic displays 231. The graphical user interface 200 may include more or fewer... FIG. 3 The example graphical interfaces 202 and 204 are shown in the image.

[0084] In addition to setting the voltage, the example control circuit system / controller can also recommend a material thickness corresponding to the selected welding parameters and display that material thickness on display 231. For example... FIG. 3As shown, the wire feed speed of the 381 IPM results in a voltage value of 26.4 volts and a material thickness of 5 / 16". In some examples, the display 231 can provide additional or alternative information regarding one or more welding process parameters.

[0085] The graphical user interface 200 includes a first graphical interface 202 representing a first welding parameter, such as voltage. A second graphical interface 204 represents a second welding parameter, such as wire feed speed. For example, a controller, such as the control circuitry 112, the controller 134, and / or the controller 158, can control each graphical interface 202 and 204 in response to the selector.

[0086] Each graphical interface 202 and 204 includes a flag 206, 209 representing an output value associated with the respective welding parameter (e.g., voltage or wire feed speed). During a welding process, each graphical interface 202 and 204 can display a value 216, 229, such as measured from one or more sensors, corresponding to the welding system output for the particular welding parameter. In some examples, the value 216, 229 represents an estimated, determined, or calculated value.

[0087] Each graphical interface 202 and 204 includes a graphical operating range 208, 222 representing an entire operating range of output values for the particular welding parameter (e.g., based on the particular welding power source). Within each operating range is a graphical band 210, 225 providing a visual representation of the operating range, which is bounded by a calculated or determined upper limit 212, 226 and a lower limit 214, 228, which are calculated for the particular welding parameter (e.g., based on a selected range tolerance).

[0088] FIG. 4 A flowchart representing example machine-readable instructions 300 are provided that can be executed by FIG. 1A the example welding system 100 of FIG. 1B the example welding system 152, and / or FIG. 1C the example welding system 154 for implementing one or more ranges during a welding process. The example instructions 300 can be stored in the storage device(s) 123 and / or the memory 124 and executed by the processor(s) 120 of the control circuitry 112. The example instructions 300 are described below with reference to the system of FIGS. 1A-3 FIG. 1.

[0089] In block 302, control circuitry (e.g., control circuitry 112, 152, 154) receives a selection of a weld parameter value associated with a first weld parameter of one or more weld 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).

[0090] In block 304, the control circuitry determines whether a range auto-lock feature has been activated. If not, the process returns to block 302 to receive a weld parameter value. If so, the process proceeds to block 306, in which the control circuitry receives a range tolerance selected from one or more range tolerances associated with the first weld parameter. For example, the range tolerance can be received from a user input and / or a welding program (e.g., via one or more selection tools, such as user interface 114, memory 124, a remote computer via network interface 117, and / or the range tolerance selection tool of FIG. 1). FIGS. 2A-2C In some examples, a single range tolerance is available for use with each applicable weld parameter, such that the limits for each weld parameter are calculated using the same calculation method (e.g., a certain percentage value higher and lower than the selected weld parameter).

[0091] In block 308, the control circuitry (e.g., via range tolerance engine 129) calculates or determines an upper limit value and a lower limit value for the range of values based on the selected range tolerance and the selected weld parameter value.

[0092] In block 310, the control circuitry can optionally store the calculated or determined limits in memory as a custom range. In some examples, the custom limits are designated with an identification in block 312. In block 314, a list of custom ranges can be accessed, scrolled, and selected according to the identification of the custom range, thereby allowing the stored custom ranges to be easily recalled and employed (e.g., via an interface and / or selection tool).

[0093] In block 316, the control circuitry then employs the calculated or determined limits to control the power supply to deliver power and / or to control the wire feeder to advance an electrode wire based on the calculated or determined limits and the selected weld parameter value.

[0094] The present apparatus and / or methods can be realized in hardware, software, or a combination of hardware and software. The present methods and / or systems can be realized in a centralized fashion in at least one computing system, processor, and / or other logic circuitry, or in a distributed fashion where different elements are spread across several interconnected computing systems, processors, and / or other logic circuitry. Any kind of computing system, or other apparatus adapted for carrying out the methods described herein, is suited to perform the methods described herein. A typical combination of hardware and software can be a processing system with a program, or other code, that, when being loaded and executed, controls the processing system such that it carries out the methods described herein. Another typical implementation can comprise a special purpose-welding power supply having a programmed microprocessor or microcontroller with a program, or other code, that, when being loaded and executed, controls the special purpose-welding power supply such that it carries out the methods described herein. Still another typical implementation can include an application-specific or chip set integrated with a processing system and / or a special purpose-welding power supply, the integrated circuit comprising a programmed processor and / or associated memory and / or logic circuitry to control that special purpose-welding power supply such that it carries out the methods described herein. Some embodiments can include a non-transitory machine- readable (e.g., computer-readable) medium (e.g., flash memory, optical disk, magnetic storage disk, and the like) having stored thereon one or more lines of code executable by a machine, thereby causing the machine to perform processes described herein. As used in this document, the term "non-transitory machine-readable medium" is defined to include all mediums that are tangible and non-transitory. It is understood that all business methods described herein, including those claimed by the express language of the claims, have sufficient physical components (e.g., hardware) that convey logic information and sufficient capacity to store that logic information; that a machine is required to be physically constructed to perform the activities; and that the activities require physical manipulations by physical components of the machine to affect that transfer and transformation of the machine. The apparatus can be any kind of device that is able to store and execute program code.

[0095] The control circuitry can identify a welding condition for a given weld and automatically seek an optimal value for one or more welding parameters for the welding condition. An example control circuit implementation can be an Atmel Mega 16 microcontroller, an STM32F407 microcontroller, a field programmable logic circuit, and / or any other control or logic circuit capable of executing instructions that run welding control software. The control circuit can also be implemented in analog circuitry and / or a combination of digital and analog circuitry. Examples are described herein with reference to various types of welders, but these examples can be used or modified for use in any type of high frequency switching power supply.

[0096] While the present methods and / or systems have been described with reference to certain implementations, it is understood that various changes can be made and equivalents can be substituted for elements without departing from the scope of the present methods and / or systems. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, blocks and / or components of disclosed examples can be combined, divided, re-arranged, and / or otherwise modified. Therefore, the present methods and / or systems are not limited to the particular implementations disclosed. Instead, the present methods and / or systems will include all implementations that fall within the scope of the claims, both literally and under the doctrine of equivalents.

Claims

1. A welding system, comprising: A control circuit system, configured to control a power supply based on a range of values ​​associated with one or more welding parameters, is configured to: Receive a range tolerance selected from one or more range tolerances associated with the selected welding parameter values ​​of the one or more welding parameters; Based on the selected range tolerance, the selected welding parameter values, and the welding parameter type among the one or more welding parameters associated with the value range, an upper and lower limit value for the value range is calculated; and The power supply is controlled based on the value range and the selected welding parameter values.

2. The welding system as claimed in claim 1, wherein, The one or more range tolerances include strict range tolerance, standard range tolerance, or wide range tolerance.

3. The welding system as described in claim 2, wherein, The control circuitry is further configured to adjust the range tolerance between the lower limit of the strict range tolerance and the upper limit of the wide range tolerance in response to an input.

4. The welding system as claimed in claim 3, wherein, The input is a change in one of the one or more welding parameters.

5. The welding system as claimed in claim 3, wherein, The input is operator input from a user interface, which includes one or more of a knob, a touchscreen panel, or a dial.

6. The welding system as claimed in claim 2, wherein, The strict range tolerance is narrower than the standard range tolerance, and the standard range tolerance is narrower than the wide range tolerance.

7. The welding system as claimed in claim 1, wherein, The control circuit system is further configured to calculate the upper limit value and the lower limit value such that a predetermined value is added to the selected welding parameter value or subtracted from the selected welding parameter value, respectively.

8. The welding system of claim 7, wherein, The predetermined value includes a first predetermined value and a second predetermined value. The first predetermined value is added to the selected welding parameter value, and the second predetermined value is subtracted from the selected welding parameter value, wherein the first predetermined value and the second predetermined value are different.

9. The welding system as claimed in claim 1, wherein, The control circuit system is further configured to calculate the upper limit value and the lower limit value by: Add a first percentage of the absolute value of the selected welding parameter value to the selected welding parameter value; or The second percentage is the absolute value of the selected welding parameter value minus the selected welding parameter value.

10. The welding system of claim 1, wherein, The one or more welding parameters further include a second welding parameter, the welding parameter being selected from a first plurality of range tolerances among the one or more range tolerances, and the second welding parameter being selected from a second plurality of range tolerances among the one or more range tolerances, the second plurality of range tolerances being different from the first plurality of range tolerances.

11. The welding system of claim 1, wherein, The one or more welding parameters include one or more of the following: 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. The welding system of claim 1, wherein the calculation includes: Receive the range value of the selection associated with the selected range tolerance; Receive welding parameter modification values ​​associated with the welding parameter type; The first predetermined value and the second predetermined value are calculated by modifying the selected range value using the welding parameter modification value; The first predetermined value is added to the selected welding parameter value to calculate the upper limit value for the value range; as well as The second predetermined value is subtracted from the selected welding parameter value to calculate the lower limit value for the value range.

13. The welding system of claim 1, wherein the control circuit calculates the upper limit value and the lower limit value by: Access a list of welding parameter values ​​associated with the welding parameter type, the list of welding parameter values ​​including a listed upper limit value or a listed lower limit value associated with each welding parameter value; The selected welding parameter value is compared with the list of welding parameter values; and Based on the welding parameter values ​​and the listed upper or lower limits, determine at least one of the upper or lower limits.

14. A welding system comprising: A power source configured to deliver power to a welding torch based on one or more welding parameters; A wire feeder configured to advance an electrode wire into the welding torch based on one or more welding parameters; as well as A control circuit system, configured to control the power supply or the wire feeder based on a range of values ​​associated with the one or more welding parameters, is configured to: Receive a selection of a welding parameter value associated with a first welding parameter among the one or more welding parameters; Receive a range tolerance selected from one or more range tolerances associated with the first welding parameter; Receives the welding process type selected from one or more welding process types; The upper and lower limits of the value range are calculated or determined based on the selected welding process type, the selected range tolerance, and the selected welding parameter values. and The power supply is controlled to deliver power or the wire feeder is controlled to advance the electrode wire based on the value range and the selected welding parameter value.

15. The welding system of claim 14, wherein, The control circuit system is further configured as follows: Specify the selected welding parameter values ​​and their corresponding ranges as custom welding parameter settings; and The selected welding parameter value and the corresponding value range are stored in a list of values ​​associated with one or more custom welding parameters.

16. The welding system of claim 15, wherein, The control circuit system is further configured as follows: Receive input corresponding to the custom welding parameter settings; and The power supply is controlled to deliver power or the wire feeder is controlled to advance the electrode wire based on the custom welding parameter settings.

17. The welding system of claim 14, wherein, The control circuit system is further configured as follows: Receive input related to the welding process type; and The value range of one or more welding parameters is calculated or determined, at least in part, based on the range tolerance associated with one or more welding parameters of the welding process type.

18. The welding system of claim 17, wherein, The welding process type input device includes one or more welding processes selected from gas shielded metal arc welding (GMAW), gas tungsten inert welding (GTAW), plasma cutting, carbon arc air cutting (CAC-A), or electrode welding as optional welding process types.

19. The welding system of claim 14, wherein, The control circuit system is further configured as follows: Receive input corresponding to one or more default settings for the one or more welding parameters; Access the default settings from a list of values ​​associated with the one or more welding parameters; and The power supply is controlled to deliver power or the wire feeder is controlled to advance the electrode wire based on one or more of the default settings.

20. The welding system of claim 14, wherein, The control circuit system is further configured as follows: Receive a selection of a second welding parameter value associated with a second welding parameter among the one or more welding parameters; Receive a second range tolerance selected from one or more range tolerances associated with the second welding parameter; The upper and lower limits of the second value range are calculated or determined based on the selected range tolerance and the selected second welding parameter value. and The power supply is controlled to deliver power or the wire feeder is controlled to advance the electrode wire based on the second value range and the selected second welding parameter value.

21. A welding system, comprising: A wire feeder configured to advance an electrode wire to a welding torch based on one or more welding parameters; as well as A control circuit system, configured to control the wire feeder based on a range of values ​​associated with the one or more welding parameters, is configured to: Receive a selection of a welding parameter value associated with a first welding parameter among the one or more welding parameters; Receive a range tolerance selected from one or more range tolerances associated with the first welding parameter; The upper and lower limits of the value range are determined based on the selected range tolerance and the selected welding parameter values, and the determination includes: Access the list of welding parameter values ​​corresponding to the upper or lower limit values. The selected welding parameter value is compared with the list item of the welding parameter value, and Based on the values ​​in the list and the welding parameter values, determine one or more of the upper limit value or the lower limit value; and The wire feeder is controlled to advance the electrode wire based on the value range and the selected welding parameter value.

22. A welding system, comprising: A control circuit system for controlling a power supply or wire feeder based on a range of values ​​associated with one or more welding parameters, the control circuit system being configured to: Receive a range tolerance selected from a plurality of range tolerances associated with the one or more welding parameters; The upper and lower limits are calculated or determined based on the range tolerance of each of the one or more welding parameters; and The power supply is controlled to deliver power or the wire feeder is controlled to advance the electrode wire based on one or more welding parameters.

23. A welding system, comprising: A power source configured to deliver power to a welding torch based on one or more welding parameters; A wire feeder configured to advance an electrode wire into the welding torch based on one or more welding parameters; as well as A control circuit system configured to control the power supply or the wire feeder based on one or more value ranges associated with the one or more welding parameters, the control circuit system being configured to: Receive a first selection of a welding parameter value associated with a first selection of the welding parameter for the first selection of the one or more welding parameters; Receive a second selection of a welding parameter value associated with a second selected welding parameter of the one or more welding parameters; Receive a range tolerance selected from one or more range tolerances associated with the first selected welding parameter and the second selected welding parameter; Receives the welding process type selected from one or more welding process types; Based on the selected welding process type, the selected range tolerance, the first welding parameter type of the first selected welding parameter, and the first selected welding parameter value, calculate the first upper limit and the first lower limit of the first value range, where the first value range corresponds to the first selected welding parameter value. Based on the selected welding process type, the selected range tolerance, the second welding parameter type of the second selected welding parameter, and the second selected welding parameter value, a second upper limit and a second lower limit value of the second value range are calculated, where the second value range corresponds to the second selected welding parameter value, wherein: The first ratio of the first upper limit value to the first selected welding parameter value is different from the second ratio of the second upper limit value to the second selected welding parameter value; The third ratio of the first lower limit value to the first selected welding parameter value is different from the fourth ratio of the second lower limit value to the second selected welding parameter value; or The first ratio is different from the second ratio, and the third ratio is different from the fourth ratio; and Based on the first value range, the first selected welding parameter value, the second value range, and the second selected welding parameter value, the power supply is controlled to deliver power or the wire feeder is controlled to advance the electrode wire.

24. The welding system of claim 23, wherein the first welding parameter type includes at least one 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; The second welding parameter type includes at least one 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; and The range tolerances for the selection include a first range tolerance associated with the first welding parameter and a second range tolerance associated with the second welding parameter.

Images