System and method for controlling a welding-type power supply using an AC waveform and / or a DC pulse waveform

Abstract

An example welding-type power supply includes: a power conversion circuit system, the power conversion circuit system being configured to convert input power into welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform; an interface, the interface being configured to receive an input representing a selected frequency of the AC waveform or the pulse waveform; and a control circuit system, the control circuit system being configured to: determine an amperage parameter of the welding-type power; determine a frequency range of the AC waveform or the pulse waveform based on the amperage parameter; control the interface to output an indication of the selected frequency relative to the determined frequency range; and control the power conversion circuit system to output the welding-type power at the selected frequency and based on the amperage parameter.

Description

Background Art

[0001] The present disclosure relates generally to welding-type systems using repetitive waveforms, and more particularly to systems and methods for controlling welding-type power supplies using AC waveforms and / or DC pulsed waveforms. Summary of the invention

[0002] A system and method for controlling a welding-type power supply using an AC waveform and / or a DC pulse waveform is disclosed, substantially as illustrated by and described in conjunction with at least one of the accompanying drawings, as more fully set forth in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 is a schematic diagram of an example welding system including a welding-type power supply configured to output welding-type power in accordance with aspects of the present disclosure.

[0004] Figure 2A It is possible to implement Figure 1 An example user interface of a user interface for enabling an operator to adjust one or more parameters of a welding-type output waveform and / or output an indication of the selected parameter relative to a determined parameter range.

[0005] Figure 2B Example user interface showing frequency changes in response to selected amperage

[0006] Figure 2C It is possible to implement Figure 1 Another example user interface of a user interface for enabling an operator to adjust one or more parameters of a welding-type output waveform and / or output another type of indication of the selected parameter relative to a determined parameter range.

[0007] Figure 2D It is possible to implement Figure 1 Another example user interface of a user interface for outputting an indication of a selected frequency relative to a determined frequency range.

[0008] Figure 3A is a graph, which means that Figure 1 Example tables or functions used by a welding-type power supply for determining a frequency parameter, a frequency range, an amperage parameter, and / or an amperage range.

[0009] Figure 3B is a graph, which means that Figure 1 Another example table or function used by a welding-type power supply of is used to determine a frequency parameter, a frequency range, an amperage parameter, and / or an amperage range.

[0010] Figure 3C is a graph, which means that Figure 1 Another multi-dimensional table or function used by a welding-type power supply of the invention is used to determine a frequency parameter, a frequency range, an amperage parameter, and / or an amperage range based on one or more additional parameters.

[0011] Figure 4 is a flow chart showing the Figure 1 Example machine readable instructions executed by a welding-type power supply for selecting and controlling the frequency of an output waveform.

[0012] Figure 5 is a flow chart showing the Figure 1 Example machine readable instructions executed by a welding-type power supply for determining whether a frequency modification is acceptable based on one or more predetermined relationships.

[0013] Figure 6 is a flow chart showing the Figure 1 Example machine readable instructions executed by a welding-type power supply for controlling an interface to output an indication of a selected frequency relative to a determined range based on one or more predetermined relationships.

[0014] Figure 7 is a flow chart showing the Figure 1 Example machine readable instructions executed by a welding-type power supply for selecting and controlling an amperage parameter of an output waveform.

[0015] Figure 8 is a flow chart showing the Figure 1 Example machine readable instructions executed by a welding-type power supply for determining whether an amperage modification is acceptable based on one or more predetermined relationships.

[0016] Fig. 9 is a flow chart showing the Figure 1 Example machine readable instructions executed by a welding-type power supply for controlling an interface to output an indication of a selected amperage relative to a determined range based on one or more predetermined relationships.

[0017] The drawings are not drawn to scale. Where appropriate, the same or similar reference numbers are used in the drawings to represent similar or identical elements. DETAILED DESCRIPTION

[0018] Gas tungsten arc welding (GTAW), also known as TIG welding, enables the welding operator to use a cyclic waveform that repeats based on a selected frequency and / or a non-cyclic waveform that occurs based on a selected frequency. For example, the operator can select the frequency of the AC waveform and / or the number of pulses per second (referred to herein as the "frequency" of the DC pulse waveform) for an AC waveform or a DC pulse waveform. Conventional welding power supplies enable the operator to select a frequency within the capabilities of the welding power supply. However, in certain parameter ranges and / or parameter combinations, the resistance and / or inductance of the welding circuit can result in poor welding performance.

[0019] As used herein, "amperage" refers to the amount of welding-type electrical current and may include instantaneous current, average current, RMS current, peak current, electrode negativity (EN) current, and / or electrode positive (EP) current.

[0020] The disclosed methods and apparatus reduce the likelihood of poor welding conditions when using AC and / or DC pulse waveforms by: 1) automatically selecting one or more AC and / or DC pulse parameters in response to changes in other parameters; and / or 2) providing an operator with an indication of the value of the selected parameter or the value of the modified parameter relative to an empirically determined acceptable range of values ​​for the selected parameter or the modified parameter. In some examples, the welding power supply stores one or more tables, algorithms, and / or other data representing a predetermined relationship between waveform frequency and (multiple) amperage parameters. The predetermined relationship may include: 1) a 1:1 correspondence between amperage and frequency for automatically selecting frequency based on amperage; 2) a preferred or optimal combination of frequency and amperage (e.g., a frequency range for a given amperage, an amperage range for a given frequency, etc.); 3) an acceptable (e.g., non-most efficient, non-most preferred) combination of frequency and amperage; and / or 4) an unacceptable or disallowed combination of frequency and amperage. These relationships, combinations, and / or ranges may be selected based on other parameters or conditions (eg, measured inductance, waveform type, etc.).

[0021] In some example systems and methods, the frequency of the AC and / or pulse waveform is automatically controlled or selected based on a commanded amperage parameter, such as a target current. The dependency of the frequency on the commanded amperage parameter may be based on average current, RMS current, peak current, electrode negativity (EN) current, and / or electrode positivity (EP) current. Additionally or alternatively, the amperage may be controlled or selected based on the commanded frequency.

[0022] In some examples, the frequency is automatically and synchronously adjusted in response to changes to the preset amperage (e.g., via an operator interface, via a remote control, etc.). Additionally or alternatively, the welding system can enable an operator to select one of a plurality of dependency levels (e.g., low, medium, high), wherein different dependency levels have different relationships (e.g., slopes) between amperage and frequency.

[0023] While lower frequencies and / or lower currents are less likely to be adversely affected by the inductance of the welding circuit than higher frequencies and / or higher currents, lower frequencies can result in poorer welding performance. Some example systems and methods impose a lower limit on frequency. Additionally or alternatively, a welding power supply can impose an upper limit on frequency to avoid operating in an amperage and frequency range that exceeds the power supply's ability to drive current as required by the waveform.

[0024] In some examples, the frequency and / or amperage can be controlled based on additional parameters, such as pulse peak current time, pulse peak current percentage, pulse background current time, pulse background current percentage, AC waveform type, or welding circuit inductance. The additional parameters can be reflected in a predetermined relationship stored in the welding power supply for control and / or notification.

[0025] In addition to or as an alternative to automatically controlling frequency based on an amperage parameter (and / or vice versa), example systems and methods may output an indication of a selected frequency (or amperage) relative to a frequency range determined based on the amperage (or frequency).

[0026] As used herein, "power conversion circuitry" and / or "power conversion circuitry" 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. The power conversion circuitry may include power limiting circuitry, output selection circuitry, measurement and / or control circuitry, and / or any other circuitry for providing appropriate features.

[0027] As used herein, the terms "first" and "second" may be used to list different components or elements of the same type and do not necessarily imply any particular order. For example, although in some examples a first time appears before a second time within a period of time, the terms "first time" and "second time" do not imply any particular order in which the first time or the second time appear relative to each other within the period of time.

[0028] As used herein, the term "welding type system" includes any device capable of supplying power suitable for welding, plasma cutting, induction heating, air blow 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, etc., as well as control circuit systems and other auxiliary circuit systems associated therewith.

[0029] 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-type power supply" and / or "power supply" refers 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, etc., as well as control circuit systems and other auxiliary circuit systems associated therewith.

[0030] As used herein, "circuit" or "circuitry" includes any analog and / or digital components, power and / or control elements (such as a microprocessor, digital signal processor (DSP), software, etc.), discrete components and / or integrated components, or multiple parts and / or combinations thereof.

[0031] As used herein, the terms "control circuitry," "control circuitry," and / or "controller" 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 circuitry or control circuitry may be located on one or more circuit boards that form part or all of a controller and is 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.

[0032] As used herein, the term "memory" includes volatile and non-volatile memory devices and / or other storage devices.

[0033] As used herein, the terms "torch", "welding torch", "welding tool" or "welding-type tool" refer to a device configured to be manipulated to perform welding-related tasks, and may include a handheld welding torch, a robotic welding torch, a welding gun, a scraping tool, a cutting tool, or other devices for generating a welding arc.

[0034] 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), spraying, short circuiting, CAC-A, scraping process, cutting process, and / or any other type of welding process.

[0035] The disclosed example welding-type power supply includes: a power conversion circuit system configured to convert input power into welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform; an interface configured to receive an input representing a selected frequency of the AC waveform or the pulse waveform; and a control circuit system configured to: determine an amperage parameter of the welding-type power; determine a frequency range of the AC waveform or the pulse waveform based on the amperage parameter; control the interface to output an indication of the selected frequency relative to the determined frequency range; and control the power conversion circuit system to output the welding-type power at the selected frequency and based on the amperage parameter.

[0036] In some examples, each cycle of the AC waveform includes an electrode negative portion and an electrode positive portion. In some example welding-type power supplies, the amperage parameter includes at least one of: average current, root mean square (RMS) current, peak current, electrode negative peak current, electrode negative commutation current, electrode positive peak current, or electrode positive commutation current.

[0037] In some example welding-type power supplies, the interface is configured to receive an amperage parameter. In some example welding-type power supplies, the control circuit system is configured to limit the selection of the frequency via the operator interface based on at least one of an upper frequency limit or a lower frequency limit. Some example welding-type power supplies further include an output device configured to output a notification in response to determining that the difference between the selected frequency and the frequency limit is less than a threshold difference.

[0038] In some example welding-type power supplies, the control circuit system is configured to determine an inductance of a welding-type circuit to which the power conversion circuit system is coupled to output welding-type power, and the control circuit system is configured to determine a frequency based on an amperage parameter and the determined inductance. In some example welding-type power supplies, the control circuit system is configured to determine at least one of a pulse peak current time, a pulse peak current percentage, a pulse background current time, a pulse background current percentage, an AC waveform type, or a welding circuit inductance, wherein the control circuit system is configured to determine the frequency based on the amperage parameter and at least one of the pulse peak current time, the pulse peak current percentage, the pulse background current time, the pulse background current percentage, the AC waveform type, or a welding circuit inductance.

[0039] In some example welding-type power supplies, each cycle of the pulse waveform includes a peak current and a background current. In some example welding-type power supplies, the control circuit system is configured to determine a frequency range of the AC waveform or the pulse waveform based on a selected one of a plurality of predetermined relationships between frequency and amperage parameters.

[0040] Some disclosed example welding-type power supplies include: a power conversion circuit system configured to convert input power into welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform; an interface configured to receive an input representing a selected amperage; and a control circuit system configured to: determine a frequency of the AC waveform or the pulse waveform; determine an amperage range based on the frequency of the AC waveform or the pulse waveform; control the interface to output an indication of the selected amperage relative to the determined amperage range; and control the power conversion circuit system to output welding-type power at the selected amperage and based on the frequency.

[0041] In some examples, each cycle of the AC waveform includes an electrode negative portion and an electrode positive portion. In some example welding-type power supplies, the amperage parameter includes at least one of: average current, root mean square (RMS) current, peak current, electrode negative peak current, electrode negative commutation current, electrode positive peak current, or electrode positive commutation current.

[0042] In some example welding-type power supplies, the interface is configured to receive the frequency. In some example welding-type power supplies, the control circuit system is configured to limit the selection of amperage via the operator interface based on at least one of an upper amperage limit or a lower amperage limit. Some example welding-type power supplies further include an output device configured to output a notification in response to determining that a difference between the selected amperage and the amperage limit is less than a threshold difference.

[0043] In some example welding-type power supplies, the control circuit system is configured to determine an inductance of a welding-type circuit to which the power conversion circuit system is coupled to output welding-type power, and the control circuit system is configured to determine the amperage based on the frequency and the determined inductance. In some example welding-type power supplies, the control circuit system is configured to determine at least one of a pulse peak current time, a pulse peak current percentage, a pulse background current time, a pulse background current percentage, an AC waveform type, or a welding circuit inductance, wherein the control circuit system is configured to determine the amperage based on the frequency and at least one of the pulse peak current time, the pulse peak current percentage, the pulse background current time, the pulse background current percentage, the AC waveform type, or the welding circuit inductance.

[0044] In some example welding-type power supplies, each cycle of the pulse waveform includes a peak current and a background current. In some example welding-type power supplies, the control circuit system is configured to determine the amperage range of the AC waveform or the pulse waveform based on a selected one of a plurality of predetermined relationships between frequency and amperage parameters.

[0045] Turning now to the accompanying drawings, Figure 1 1 is a block diagram of an example welding system 100 having a welding-type power supply 102, a remote interface 104, and a welding torch 106. The welding system 100 provides power, control, and / or supplies consumables to a welding application. Figure 1 In the example of , the power supply 102 directly supplies welding-type output power to the welding torch 106. The welding torch 106 is configured for gas tungsten arc welding (GTAW), which can be used to perform a welding process including a DC welding-type current, a pulsed DC welding-type current waveform, and / or an AC waveform. An example DC pulse waveform that can be output by the power supply 102 has a peak phase at a peak current and a background phase at a background current, and one pulse cycle includes a peak phase and a background phase.

[0046] The power supply 102 receives main power 108 (e.g., from an AC grid, an engine / generator set, a battery, or other energy generation or storage device, or a combination thereof), conditions the main power, and provides output power to one or more welding devices according to the needs of the system 100. The main power 108 can be supplied from a location remote from the site (e.g., the main power can be derived from the grid). The power supply 102 includes a power conversion circuit system 110, which can include a transformer, a rectifier, a switch, etc., which can convert AC input power into AC and / or DC output power as dictated by the needs of the system 100 (e.g., a specific welding process and protocol). The power conversion circuit system 110 converts the input power (e.g., the main power 108) into welding-type power based on a target amperage (e.g., a welding current set point), and outputs the welding-type power via a welding circuit.

[0047] The power supply 102 includes a control circuit system 112 for controlling the operation of the power supply 102. The power supply 102 also includes a user interface 114. The control circuit system 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, frequency, pulse peak current time, pulse peak current percentage, pulse background current time, pulse background current percentage, AC waveform type, AC balance, welding circuit inductance, etc.). The user interface 114 can use one or more input devices 115 to receive input, such as via a keypad, keyboard, physical button, switch, knob, mouse, keyboard, keypad, touch screen (e.g., software button), voice activation system, wireless device, etc. In addition, the control circuit system 112 controls the operating parameters based on the user's input and based on other current operating parameters. Specifically, the user interface 114 may include a display 116 for presenting, showing, or indicating information to an operator.

[0048] Similarly, the example remote interface 104 may include a user interface 134 having one or more input devices 135 and a display 136. The user interface 134, input device(s) 135, and / or display 136 may be similar, the same, or different than the user interface 114, input device(s) 115, and / or display 116.

[0049] The control circuit system 112 may also include an interface circuit system for transmitting data to other devices in the system 100, such as the remote interface 104. For example, in some cases, the power supply 102 communicates wirelessly with the remote interface 104. Further, in some cases, the power supply 102 communicates with the remote interface 104 using a wired connection, such as by using a network interface controller (NIC) to transmit data via a network (e.g., Ethernet, 10baseT, 10base100, etc.). In some examples, the control circuit system 112 communicates with the remote interface 104 via a welding circuit.

[0050] The control circuit system 112 includes at least one controller or processor 120 that controls the operation of the power supply 102. The control circuit system 112 receives and processes a plurality of inputs associated with the performance and requirements of the system 100. The processor 120 may 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 may include one or more digital signal processors (DSPs).

[0051] The example control circuit system 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 devices) may include ROM, flash memory, hard disk drives, and / or any other suitable optical storage media, magnetic storage media, and / or solid-state storage media, and / or combinations thereof. The storage device 123 stores data (e.g., data corresponding to a welding application), instructions (e.g., software or firmware for executing a welding process), and / or any other suitable data. Examples of stored data for a welding application include a predetermined relationship between frequency and amperage, such as one or more lookup tables, as described in more detail below.

[0052] The memory device 124 may 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 may store a variety of information and may be used for a variety of purposes. For example, the memory device 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, the storage device 123 and / or the memory device 124 may store one or more control schemes for various welding processes along with associated settings and parameters.

[0053] In some examples, the gas supply 128 provides a shielding gas, such as argon, helium, carbon dioxide, etc., depending on the welding application. The shielding gas flows to a valve 130, which controls the flow of the gas and, if desired, can be selected to allow the amount of gas supplied to the welding application to be adjusted or regulated. The valve 130 can be opened, closed, or otherwise operated by the control circuit system 112 to allow, prohibit, or control the flow of a gas (e.g., shielding gas) through the valve 130. The shielding gas leaves the valve 130 and flows to the welding torch 106 via a cable 138 (which, in some embodiments, can be assembled with the welding power output), thereby providing shielding gas for the welding application. In some examples, the welding system 100 does not include the gas supply 128, the valve 130, and / or the cable 138.

[0054] exist Figure 1 In the example of , the power supply 102 includes a communication transceiver 118, and the remote interface 104 includes a communication transceiver 119. The communication transceivers 118, 119 each include a corresponding receiver circuit 121 and a corresponding transmitter circuit 122. The example communication transceivers 118, 119 enable the remote interface 104 to transmit commands to the power supply 102 and / or receive information from the power supply 102. Example commands may include commands for setting parameters and / or otherwise configuring the power supply 102. The remote interface 104 can receive information about the configuration of the power supply 102.

[0055] The remote interface 104 further includes a control circuit system 132, which may include one or more processors 120, one or more storage devices 123, and / or memory 124, and / or may store and execute machine-readable instructions 125. The control circuit system 132, (multiple) processors 120, (multiple) storage devices 123, and / or memory 124 may be similar to, the same as, or different from the control circuit system 112, (multiple) processors 120, (multiple) storage devices 123, and / or memory 124 of the power supply 102.

[0056] The welding torch 106 delivers welding power and / or shielding gas for a welding application. The welding torch 106 is used to establish a welding arc between the welding torch 106 and a workpiece 146. The welding cable 140 couples the welding torch 106 to the power conversion circuit system 110 to conduct current to the welding torch 106. The work cable 148 couples the workpiece 146 to the power supply 102 (e.g., coupled to the power conversion circuit system 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.

[0057] In some examples, one or more sensors 147 are included in or connected to the welding torch 106 to monitor one or more welding parameters (e.g., power, voltage, current, inductance, impedance, etc.) to notify the control circuit system 132 and / or 112 during the welding process.

[0058] To assist a welding operator in properly configuring the welding-type power supply 102 (e.g., welding parameters) for an AC waveform or DC pulse process, the example storage device(s) 123 may store a table 126 or other data representing the relationship between frequency and amperage. The table 126 may define the relationship for different values ​​of other parameters, such as welding circuit inductance, waveform characteristics (e.g., AC waveform shape, peak current and / or background current, and / or dwell time of a pulse, etc.), and / or any other variable. The example table 126 may be populated based on empirical testing using different combinations of welding parameters.

[0059] Figure 2A It is possible to implement Figure 1 An example user interface 200 of the user interface 114, 134 is used to enable an operator to adjust one or more parameters of a welding-type output waveform and / or output an indication of the selected parameter relative to a determined parameter range. Figure 2A The example user interface 200 includes a display 202, input buttons 204a to 204e, 206, 208, 210, and an input knob 212. The example buttons 204a to 204e, 206, 208, 210, and input knob 212 may implement Figure 1 Input devices 115, 135.

[0060] The example buttons 204a to 204e enable the operator to select one or more welding parameters to adjust or recall (e.g., by recalling a welding schedule or stored parameter set). Once a parameter is selected, the example knob 212 receives input for changing the value of the parameter, such as by increasing (e.g., incrementing) or decreasing (e.g., decrementing) the value of the parameter and / or selecting between discrete parameter values. For example, the operator can turn the knob 212 to select an AC waveform or a DC pulse process, to change the welding amperage, to change the AC or DC pulse frequency, and / or to change any other parameter.

[0061] Button 208 may be selected to confirm the selected parameter. Button 208 enables navigation, such as by canceling a parameter change and / or returning to a previous menu.

[0062] The example button 210 may be selected to enable or disable an automatic configuration mode in which the control circuit system 112, 132 automatically configures one or more parameters in response to changes in one or more other parameters. For example, when the automatic configuration mode is selected, the control circuit system 112, 132 may respond to changes in the amperage parameter (e.g., received via the knob 212) with corresponding changes in the frequency for the AC and / or DC pulsed process. Similarly, the control circuit system 112, 132 may respond to changes in the frequency parameter by automatically configuring the amperage. To determine the automatic changes, the example control circuit system 112, 132 accesses a predetermined relationship stored in the storage device(s) 123 and / or the memory 124, such as a relationship between amperage and frequency. The predetermined relationship may be selected from a plurality of predetermined relationships based on other selected parameters such as the type of welding process (e.g., AC, DC pulsed), the measured inductance, and / or any other parameter. The operator may be allowed to change the parameter according to the automatically configured value, or the operator may be prevented from changing the automatically configured value without disabling the automatic configuration mode.

[0063] When the auto-configuration mode is disabled (or deselected), the control circuitry 112, 132 allows parameters specified in a predetermined relationship to be independently set. For example, the control circuitry 112, 132 does not change frequency based on changes in amperage, and does not change amperage based on changes in frequency.

[0064] exist Figure 2AIn the example of , the display 202 presents a graph 214 indicating a selected value of a parameter (e.g., frequency) relative to a frequency range. The example graph 214 includes an indicative graphic 216 within a trapezoid 218 representing a range of values. A center portion 220 of the trapezoid represents a preferred or optimal value of the parameter according to a selected predetermined relationship. A left portion 222 and a right portion 224 of the trapezoid 218 represent deviations of the parameter value relative to the value represented by the center portion 220. When the value of the parameter is modified (e.g., via the knob 212), the control circuit system 112, 132 updates the graph 214 based on the value of the parameter relative to the range to move the indicative graphic 216 within the trapezoid 218.

[0065] exist Figure 2A In the example of FIG. 2 , the left portion 222 and the right portion 224 may have different characteristics, such as different colors or patterns, to indicate the relative advantages or disadvantages of the corresponding parameter ranges. For example, the right portion 224 representing higher frequencies for a given amperage may be colored with a color associated with warning or disadvantage to indicate that the right portion 224 represents an unfavorable frequency range. Conversely, the left portion 222 representing lower frequencies for a given amperage may be colored with a color associated with acceptable to indicate that, although not a preferred range, the left portion 222 still represents an acceptable range.

[0066] In addition to the graph 214 , the example display 202 may also numerically display the selected value of the parameter and / or may display information to guide the operator in making changes to the selected value (eg, increasing the parameter for thinner materials, decreasing the parameter for thicker materials).

[0067] The frequency range represented by the graph 214 may be determined based on another parameter (e.g., amperage) specified in a stored predetermined relationship. For example, when the amperage parameter is selected, the control circuit system 112, 132 automatically determines the frequency range. The frequency range may include only preferred frequencies, or may include frequencies that are not most preferred but are still acceptable.

[0068] exist Figure 2A In some examples, the determined range does not include frequencies that have been set in the stored predetermined relationship. In some examples, the control circuit system 112, 132 can prevent the operator from setting the value of the frequency parameter outside the acceptable range.

[0069] Figure 2B The example user interface 200 is shown with the frequency changing in response to a selected amperage, such as an operator input to change the frequency via the knob 212. The example user interface 200 may similarly represent changes in amperage for a selected frequency.

[0070] In some examples, control circuit system 112 may update graph 214 representing frequency values ​​and frequency ranges based on changes in amperage, or vice versa. Figure 2B The indicative graphic 216 is in the right portion 224 of the graphic 214 for a given ampere number, but a change in the ampere number will cause the control circuit system 112 to recalculate the frequency range, change the frequency range represented by the graphic 214 and portions 220, 222, 224, and display the indicative graphic 216 relative to the graphic 214 based on the updated range.

[0071] Figure 2C It is possible to implement Figure 1 Another example user interface 230 of the user interface 114, 134 is used to enable an operator to adjust one or more parameters of a welding-type output waveform and / or output another type of indication of the selected parameter relative to a determined parameter range. Figure 2B An example user interface 230 includes Figure 2A The display 202, buttons 204a to 204e, 206 to 210, and the knob 212 are shown.

[0072] exist Figure 2C In the example of FIG. 2 , the display 202 presents an ampere value 232 and a frequency value 234 (e.g., the number of pulses per second for a DC pulse process). The display 202 further presents an indication 236 of the frequency value 234 relative to the determined value range. Figure 2C In the example of , indication 236 includes an indicator graphic 238 of the frequency value and a textual description 240, such as "Above Desirable Range," where changing to a frequency above the determined frequency range may result in a limited ability of power supply 102 to provide the specified pulse shape at the configured amperage. When the selected frequency is below the determined frequency range, indication 236 may include the following textual description: Changing to a frequency below the determined frequency range has a limited effect compared to changing to a frequency within the determined range.

[0073] Figure 2D It is possible to implement Figure 1 Another example user interface 250 of the user interface 114, 134 of the embodiment of the present invention is used to output an indication of the selected frequency relative to the determined frequency range. Additionally or alternatively, the user interface 250 can output an indication of the selected amperage relative to the determined amperage range.

[0074] The example user interface 250 includes output displays 252, 254 that output the selected amperage and the selected frequency. However, the displays 252, 254 may be configured to output the value of any parameter being configured by the operator, to change to output the value and / or identity of the selected parameter in response to the operator's selection of a parameter, and / or to output the value of a default parameter in response to a lack of input (e.g., within a threshold time).

[0075] The example user interface 250 further includes indicator graphics 256, 258, 260 to provide an operator with an indication of the value of the amperage or frequency relative to the determined value range of the parameter. The example indicator graphic 256 is a visual indicator graphic (e.g., a light, LED, etc.) that is illuminated when the selected frequency is considered to be a preferred (or ideal) value determined based on the selected amperage. Additionally or alternatively, the indicator graphic 256 can be configured to output an indication when the selected frequency is within the preferred (or ideal) frequency range determined by the control circuit system 112 based on the selected amperage.

[0076] The example indicator graphic 258 is a visual indicator graphic (e.g., a light, LED, etc.) that is illuminated when the selected frequency has reached (e.g., equal to) an upper limit of the frequency, wherein the upper limit is determined based on the amperage. Similarly, the example indicator 260 is a visual indicator graphic (e.g., a light, LED, etc.) that is illuminated when the selected frequency has reached (e.g., equal to) a lower limit of the frequency, wherein the lower limit is determined based on the amperage. In some examples, the control circuit system 112 controls the corresponding indicator graphic 258, 260 to illuminate when the corresponding limit is reached by the operator selecting the frequency (e.g., by increasing or decreasing the frequency via the knob 212).

[0077] The limits that trigger the indication graphics 258, 260 may be selected as limits of a preferred range and / or limits of one or more acceptable ranges. When using limits of a preferred range, the control circuit system 112 may treat the limits as "soft" limits that may be exceeded (e.g., the operator may be allowed to select a frequency value outside the range represented by the limits) while continuing to output indications via the corresponding indication graphics 258, 260. In some examples, when using limits of an acceptable range, the control circuit system 112 may treat the limits as "hard" limits that may not be exceeded, and output indications via the corresponding indication graphics 258, 260 when the selected frequency is equal to the corresponding lower frequency limit or upper frequency limit. However, the preferred frequency range may be treated as a "hard" limit, and / or the acceptable frequency range may be treated as a "soft" limit.

[0078] Although in Figure 2D256, 258, 260 are shown in the example indication graphics, but additional indication graphics and / or alternative indication graphics may be used. For example, indication graphics for both "hard" and "soft" limits, and / or for different ranges (e.g., preferred ranges and acceptable ranges) may be included.

[0079] Although the above references select frequency and frequency limit values ​​based on the selected amperage Figure 2D As described, the example user interface 250 may additionally or alternatively operate the indicator graphics 256 , 258 , 260 based on the selected amperage, relative to a range of amperages based on the selected frequency.

[0080] Any of the example interfaces 200, 230, 250 may provide other indications of the frequency determined based on the selected amperage, or provide an indication of the amperage determined based on the selected frequency. For example, the control circuit system 112 may control the determined parameter (e.g., frequency, amperage) to provide a visual indication or other indication (e.g., flashing, color, etc.) on a display or other output device that the displayed parameter (e.g., frequency, amperage) value has been automatically selected based on one or more other parameters (e.g., amperage, frequency, etc.).

[0081] Figure 3A is a diagram 300, which shows that Figure 1 Example tables or functions used by the welding power supply 102 of the present invention to determine frequency parameters, frequency ranges, amperage parameters, and / or amperage ranges. The example chart 300 may be stored in a computer program product as one or more data structures, data points, and / or any other format. Figure 1 in the storage device 123 and / or the memory 124.

[0082] The example graph 300 includes a relationship 302 , which may be stored as one or more functions and / or data points. If the control circuitry 112 , 132 has enabled the auto-configuration mode, the control circuitry 112 , 132 may respond to the selection of the amperage parameter by determining a corresponding frequency according to the relationship 302 .

[0083] The example chart 300 further illustrates ranges 304, 306, 308 representing combinations of ampere values ​​and frequency values. The example range 304 represents preferred or optimal frequency values ​​for each ampere value, or conversely, represents preferred or optimal ampere values ​​for each frequency. The example range 306 represents intermediate (e.g., non-preferred, non-optimal) frequency values ​​for each ampere value (or vice versa), and the example range 308 represents frequency values ​​at which performance is limited for each ampere value (or vice versa).

[0084] In some examples, the control circuit system 112 enables the operator to select a modified relationship 310 based on the relationship 302 (e.g., via the user interface 114 and / or the (multiple) input devices 115). For example, when the frequency value or the amperage value is automatically selected, the control circuit system 112 can replace the relationship 302 with the relationship 310. The relationship 310 can be defined using, for example, a selected percentage deviation or by a fixed deviation. An example percentage deviation can include adjusting the frequency or amperage to be a selected percentage higher or lower than the value specified by the relationship 302. Other example percentage deviations can include adjusting the frequency or amperage to be a selected percentage higher or lower than the value specified by the relationship 302 by the difference between the upper limit value and the lower limit value of the preferred range 304 (or a combination of ranges 304, 306 and / or 308), or a selected percentage higher or lower than the value specified by the relationship 302 and the upper limit value or lower limit value of the preferred range 304. Example fixed deviations may include a set frequency or amperage difference above or below the frequency specified by relationship 302 , such as X Hz or X pulses per second.

[0085] Figure 3B is a diagram 320, which indicates that Figure 1 Another example table or function used by the welding power supply 102 of the present invention is used to determine the frequency parameter, frequency range, amperage parameter, and / or amperage range. The example chart 320 can be stored as one or more data structures, data points, and / or any other format. Figure 1 in the storage device 123 and / or the memory 124.

[0086] as Figure 3A 300, the example graph 320 includes a preferred range 322 representing preferred or optimal frequency values ​​for each amperage value, an intermediate range 324 representing intermediate frequency values ​​for each amperage value, and a range 326 representing values ​​where performance is limited. Figure 3A Compared to the predetermined ranges of 322, 324, 326 having upper and lower frequency limits that change with amperage, the example ranges 322, 324, 326 have upper and lower frequency limits that change at predetermined amperage thresholds. For example, the ranges 322, 324, 326 have constant respective upper and lower frequency limits from 0 amps to 125 amps, from 125 amps to 266 amps, and from 266 amps to 425 amps. However, other amperage limits may be used.

[0087] Portions of the graph outside of the ranges 322, 324, 326 may indicate combinations of frequency and amperage that are not permitted by the control circuitry 112, 132. For example, for an output current of 100 amps, the control circuitry 112, 132 may not increase the frequency beyond 350 Hz even if an input to further increase the frequency is received via the knob 212. While the example range 324 includes a lower frequency limit, in some examples, the lower frequency limit of the range 324 is near 0 Hz, or the lowest frequency at which the power supply 102 is capable of outputting AC or DC pulsed welding power.

[0088] In some examples, if the frequency selected (e.g., via the operator interface 114, 134) is within a threshold difference of the upper frequency limit or the lower frequency limit, the control circuit system 112, 132 outputs a notification to the operator to indicate that the frequency is approaching the frequency limit. In other examples, the control circuit system 112, 132 outputs a notification to the operator when the upper frequency limit or the lower frequency limit is reached.

[0089] Figure 3C is a diagram 340, which indicates that Figure 1 Another multi-dimensional table or function used by the welding-type power supply 102 of the embodiment of the present invention is used to determine the frequency parameter, frequency range, amperage parameter, and / or amperage range based on one or more additional parameters. The example chart 340 includes pulse peak time as a third parameter, but other parameters may also be used.

[0090] as Figure 3A 300, a graph 340 includes a relationship 342 that can be used in the automatic configuration mode. The graph 340 further includes a preferred range 344 representing preferred or optimal frequency values ​​for each amperage value, an intermediate range 346 representing intermediate frequency values ​​for each amperage value, and a range 348 representing values ​​where performance is limited.

[0091] In some examples, the preferred range includes all frequencies less than the threshold current (or all frequencies that the power conversion circuitry is capable of outputting or is configured to output). For example, low currents below the threshold current do not produce distortion regardless of the frequency used by the power conversion circuitry.

[0092] Figure 4 is a flow chart showing the Figure 1 The example machine readable instructions 400 executed by the welding-type power supply 102 are used to select and control the frequency of the output waveform. The example instructions 400 can be stored in the storage device 123 and / or the memory 124 and executed by the processor(s) 120. Figure 2AThe instructions 400 are discussed with reference to the user interface 200. However, blocks 402 to 414 may be Figure 1 The example remote interface 104 is implemented.

[0093] At block 402, the control circuitry 112 determines an amperage parameter of the welding-type power to be output by the power conversion circuitry 110. For example, the control circuitry 112 may receive a selection of an amperage parameter via the knob 212 of the user interface 200. The amperage parameter may be a current set point, an average current, a root mean square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current, and / or any other current.

[0094] At block 404, the control circuit system 112 determines whether the welding-type output is configured for an AC waveform, a DC pulse waveform, or another different welding process. For example, the control circuit system 112 may be able to control the power conversion circuit system using different welding processes including DCEN, DCEP, AC and / or DC pulse waveforms, etc. If the welding-type output is not configured for an AC waveform or a DC pulse waveform (block 404), control returns to block 402.

[0095] If the welding-type output is configured for an AC waveform or a DC pulse waveform (block 404), the control circuitry 112 determines whether automatic parameter configuration is selected (eg, enabled) at block 406. For example, the control circuitry 112 may determine whether the automatic configuration button 210 is selected on the user interface 200.

[0096] If automatic parameter configuration is selected (block 406), then at block 408, the control circuitry 112 determines the frequency of the waveform based on the amperage parameter. For example, the control circuitry 112 may access a predetermined relationship such as Figure 3A The predetermined relationship 302 is used to determine a frequency corresponding to the determined amperage parameter. The predetermined relationship may be fixed, or may be selected from a plurality of predetermined relationships based on one or more other parameter values. For example, parameter values ​​that may be used to select the predetermined relationship may include pulse peak current time, pulse peak current percentage, pulse background current time, pulse background current percentage, AC waveform type, or welding circuit inductance.

[0097] In some examples, the control circuit system 112 determines the inductance of the welding-type circuit to which the power conversion circuit system 110 is coupled to output the welding-type power. For example, the control circuit system 112 can measure, calculate, and / or estimate the inductance of the welding circuit, and / or the inductance can be input by a user (e.g., via the user interface 114, 134). The control circuit system 112 can then be used to select an appropriate predetermined relationship (e.g., a three-dimensional lookup table or function, similar to Figure 3C 340) to determine the frequency based on the amperage parameter and the determined inductance.

[0098] Additionally or alternatively, the control circuit system 112 may identify during the DC pulse process (e.g., via a current sensor) that the current does not reach a peak current level or a background current level, which indicates that the inductance is too high for the selected amperage and frequency. In such an example, due to the detected higher inductance and / or the detected waveform change, the control circuit system 112 may output a warning or alarm that the current is not currently reaching the expected level, or has not reached the expected level within the expected time. Additionally or alternatively, the control circuit system 112 may automatically adjust the frequency in response to detecting that the expected waveform has not been achieved within a threshold number of pulses or cycles.

[0099] At block 410 , the control circuitry 112 sets the frequency of the waveform to the determined frequency.

[0100] After setting the frequency (block 410), or if automatic parameter configuration is not selected (block 406), at block 412, the control circuit system 112 determines whether an input for modifying the frequency has been received. For example, the control circuit system 112 may allow a change to the automatically configured frequency, or the frequency may not be automatically configured. This may be done via a control such as Figure 2A and / or Figure 2B The input device 115, 135 such as the knob 212 is used to receive an example input for modifying the frequency.

[0101] If input has been received for modifying the frequency (block 412), then at block 414, the control circuit system 112 determines whether the frequency modification is acceptable. For example, the control circuit system 112 may compare the selected frequency to one or more frequency ranges based on the amperage parameter to determine whether the combination of amperage and frequency will result in acceptable welding conditions. Figure 5 Example methods for determining whether a frequency modification is acceptable are disclosed.

[0102] If the frequency modification is acceptable (block 416), then at block 418, control circuitry 112 sets the frequency of the waveform to the modified frequency. In some examples, control circuitry 112 may, for example, Figure 2A The graph 214 of FIG. 110 outputs an indication of the modified frequency relative to the range and / or relative to the value to be automatically configured (e.g., the preferred value or the optimal value). In contrast, if the frequency modification is unacceptable (block 416), the control circuit system 112 outputs a notification that the modified frequency is outside the frequency range. For example, the control circuit system 112 may output an indication such as Figure 2B After setting the frequency (block 418) or outputting the notification (block 420), control returns to block 412.

[0103] If no input is received for modifying the frequency (e.g., a user confirms that the frequency is acceptable) (block 412), then at block 420, the control circuit system 112 determines whether welding is valid. For example, the control circuit system 112 may determine whether a welding current is flowing or whether an output voltage corresponding to an arc is present. If welding is valid (block 422), then at block 424, the control circuit system 112 controls the power conversion circuit system 110 to output welding-type power using the set frequency. The set frequency may be, for example, an automatically set frequency (block 410) or a modified frequency (block 418). Control loops back to block 422 to continue welding. If welding is not valid (block 422), control returns to block 402.

[0104] Figure 5 is a flow chart showing the Figure 1 Example machine readable instructions 500 executed by a welding-type power supply 102 for determining whether a frequency modification is acceptable based on one or more predetermined relationships. The example instructions 500 may be executed by Figure 1 The control circuit systems 112, 132 are executed to implement Figure 4 The example instructions 500 may be from Figure 4 Box 412 input.

[0105] At block 502 , the control circuitry 112 determines one or more frequency ranges based on the determined amperage parameter. For example, the control circuitry 112 may look up a predetermined relationship stored in the table 126 . Figure 3A , Figure 3B and Figure 3C An example range is shown in FIG. 10 . At block 504, the control circuit system 112 determines the selected frequency (e.g., Figure 4For example, the control circuit system 112 may determine whether the selected frequency is within the preferred frequency range based on the selected predetermined relationship. Figure 3A The corresponding preferred frequency range 304, Figure 3B The corresponding preferred frequency range 322 or Figure 3C or within any other range stored as a preferred range or optimal range.

[0106] If the selected frequency is not within the preferred frequency range (block 504), then at block 506, control circuitry 112 determines whether the selected frequency is within the permissible frequency range. For example, control circuitry 112 may determine whether the selected frequency is within the permissible frequency range based on a selected predetermined relationship, or any other range stored as an allowable or acceptable range for implementation by power conversion circuitry 110. Figure 3A The corresponding acceptable or restricted frequency ranges 306, 308, Figure 3B The corresponding acceptable or restricted frequency range 324, 326 or Figure 3C within the corresponding acceptable or restricted frequency ranges 346, 348.

[0107] If the selected frequency is within the preferred frequency range (block 504), or the selected frequency is within the allowable frequency range (block 506), then at block 508, the control circuit system 112 determines that the selected frequency is acceptable, or determines that the operator will be permitted to perform a welding operation using the selected frequency and amperage.

[0108] Conversely, if the selected frequency is neither within the preferred frequency range (box 504) nor within the allowable frequency range (box 506), then at box 510, the control circuit system 112 determines that the selected frequency is unacceptable, or determines that the operator will not be permitted to perform a welding operation using the selected frequency and amperage.

[0109] After determining whether the selected frequency is acceptable (block 508) or unacceptable (block 510), the example instructions 500 ends and returns control to Figure 4 Frame 416.

[0110] Figure 6 is a flow chart showing the Figure 1 The example machine readable instructions 600 executed by the welding-type power supply 102 are used to control the interface to output an indication of the selected frequency relative to the determined range based on one or more predetermined relationships. The example instructions 600 can be stored in the storage device 123 and / or the memory 124 and executed by the processor(s) 120. Figure 2AThe instructions 600 are discussed with reference to the user interface 200 of FIG. However, blocks 602 to 616 may be Figure 1 The example remote interface 104 is implemented.

[0111] At block 602, the control circuitry 112 determines an amperage parameter of the welding-type power to be output by the power conversion circuitry 110. For example, the control circuitry 112 may receive a selection of an amperage parameter via the knob 212 of the user interface 200. The amperage parameter may be a current set point, an average current, a root mean square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current, and / or any other current.

[0112] At block 604, the control circuit system 112 determines whether the welding-type output is configured for an AC waveform, a DC pulse waveform, or for a different welding process. For example, the control circuit system 112 may be able to control the power conversion circuit system using different welding processes including DCEN, DCEP, AC and / or DC pulse waveforms, etc. If the welding-type output is not configured for an AC waveform or a DC pulse waveform (block 604), control returns to block 602.

[0113] If the welding-type output is configured for an AC waveform or a DC pulse waveform (block 604), then at block 606, the control circuit system 112 determines a frequency range based on the amperage parameter. For example, the control circuit system 112 may determine the frequency range based on a predetermined relationship corresponding to one or more welding parameters, such as pulse peak current time, pulse peak current percentage, pulse background current time, pulse background current percentage, AC waveform type, or welding circuit inductance. The determined frequency range may be selected from one or more sub-ranges, such as a preferred range, an acceptable range, and / or a range where performance is limited, such as Figure 3A The range is 304 to 308, Figure 3B The range is 322 to 326 and Figure 3C The range 344 to 348 of FIG. In some examples, the determined frequency range is limited to the preferred range specified in table 126. In other examples, the determined frequency range may include an acceptable range, or include an acceptable range and a range where performance is limited.

[0114] At block 608, the control circuit system 112 determines whether a selection of AC or pulse frequency has been received. This can be done via a method such as Figure 2A and / or Figure 2BThe control circuit system 112 may receive an example input for selecting a frequency using an input device 115, 135 such as a knob 212 of the control circuit system 112. If a frequency selection has been received (block 608), then at block 610, the control circuit system 112 compares the selected frequency to the determined frequency range.

[0115] At block 612, the control circuitry 112 outputs an indication of the selected frequency relative to the determined frequency range. For example, the control circuitry 112 may output: Figure 2A Graphics 214; Figure 2B an indicative graphic 258 and / or a textual description 260; a visual alert, alarm, display or graphic; an audible alert, alarm or message; a communication notification (e.g., a telephone alert, email, text message, etc.); and / or any other indication (e.g., a message, alert, alarm, notification, etc.) representing the value of the frequency range determined by the selected frequency reference.

[0116] At block 614, the control circuit system 112 determines whether the selected frequency is within the determined frequency range. If the selected frequency is not within the determined frequency range (block 614), at block 616, the control circuit system 112 outputs (e.g., via the user interface 114) a notification that the selected frequency is outside the determined frequency range. The notification may be in addition to or implemented into the indication of block 612. Conversely, if the selected frequency is within the determined frequency range (block 614), at block 618, the control circuit system 112 sets the frequency of the output waveform to the selected frequency.

[0117] If a frequency selection has not been made (block 608), then after outputting the notification (block 616), or after setting the frequency (block 618), at block 620, the control circuit system 112 determines whether welding is valid. For example, the control circuit system 112 may determine whether a welding current is flowing or whether there is an output voltage corresponding to an arc. If welding is valid (block 620), then at block 622, the control circuit system 112 controls the power conversion circuit system 110 to output welding-type power using the set frequency. Control loops back to block 620 to continue welding. If welding is not valid (block 620), control returns to block 602.

[0118] Figure 7 is a flow chart showing the Figure 1 The example machine readable instructions 700 executed by the welding-type power supply 102 are used to select and control the amperage parameters of the output waveform. The example instructions 700 can be stored in the storage device 123 and / or the memory 124 and executed by the processor(s) 120. Figure 2AThe instructions 700 are discussed with reference to the user interface 200. However, blocks 702 to 718 may be Figure 1 The example remote interface 104 is implemented.

[0119] At block 702, the control circuitry 112 determines a frequency parameter of the welding-type power to be output by the power conversion circuitry 110. For example, the control circuitry 112 may receive a selection of a frequency parameter via the knob 212 of the user interface 200. The frequency parameter may be a number of pulses per second (e.g., for DC pulse operation) or a number of cycles per second (e.g., for AC operation).

[0120] At block 704 , the control circuitry 112 determines whether automatic parameter configuration is selected (eg, enabled). For example, the control circuitry 112 may determine whether the automatic configuration button 210 is selected on the user interface 200 .

[0121] If automatic parameter configuration is selected (block 704), then at block 706, the control circuitry 112 determines the amperage of the waveform based on the determined frequency. For example, the control circuitry 112 may access a predetermined relationship, such as Figure 3A The predetermined relationship 302 is used to determine the amperage corresponding to the determined frequency. The predetermined relationship may be fixed or may be selected from a plurality of predetermined relationships based on one or more other parameter values. For example, parameter values ​​that may be used to select the predetermined relationship may include pulse peak current time, pulse peak current percentage, pulse background current time, pulse background current percentage, AC waveform type, or welding circuit inductance. At block 708, the control circuit system 112 sets the amperage parameter for the welding operation to the determined amperage.

[0122] After setting the frequency (block 708), or if automatic parameter configuration is not selected (block 704), at block 710, the control circuit system 112 determines whether an input has been received to modify the amperage. For example, the control circuit system 112 may allow a change to the automatically configured amperage, or the amperage may not be automatically configured. This may be done via a control such as Figure 2A and / or Figure 2B The input device 115, 135 such as the knob 212 is used to receive example inputs for modifying the amperage.

[0123] If an input for modifying the amperage has been received (block 710), then at block 712, the control circuit system 112 determines whether the amperage modification is acceptable. For example, the control circuit system 112 may compare the selected amperage to one or more amperage ranges based on frequency to determine whether such a combination of amperage and frequency will result in acceptable welding conditions. Figure 5Example methods for determining whether an amperage modification is acceptable are disclosed.

[0124] If the amperage modification is unacceptable (block 714), then at block 716, the control circuitry 112 sets the amperage of the waveform to the modified amperage. In some examples, the control circuitry 112 may, such as via Figure 2A The graph 214 of FIG. 110 outputs an indication of the modified amperage relative to the range and / or relative to the value to be automatically configured (e.g., the preferred value or the optimal value). Conversely, if the amperage modification is unacceptable (block 714), the control circuit system 112 outputs a notification that the modified amperage is outside the amperage range. For example, the control circuit system 112 may output an indication such as Figure 2B After setting the amperage (block 716) or outputting a notification (block 718), control returns to block 710.

[0125] If no input is received to modify the amperage (e.g., the user confirms that the amperage is acceptable) (block 710), then at block 720, the control circuit system 112 determines whether the weld is valid. For example, the control circuit system 112 may determine whether a welding current is flowing or whether an output voltage corresponding to an arc is present. If the weld is valid (block 720), then at block 722, the control circuit system 112 controls the power conversion circuit system 110 to output welding-type power using the set amperage. The set amperage may be, for example, an automatically set amperage (block 716) or a modified frequency (block 708). Control repeats back to block 720 to continue welding. If the weld is not valid (block 720), control returns to block 702.

[0126] Figure 8 is a flow chart showing the Figure 1 Example machine readable instructions 800 executed by a welding-type power supply 102 for determining whether an amperage modification is acceptable based on one or more predetermined relationships. The example instructions 800 may be executed by Figure 1 The control circuit systems 112, 132 are executed to implement Figure 7 The example instructions 800 may be from Figure 7 Box 710 input.

[0127] At block 802 , the control circuitry 112 determines one or more amperage ranges based on the determined frequency. For example, the control circuitry 112 may look up a predetermined relationship stored in the table 126 . Figure 3A , Figure 3B Example ranges are shown in FIG. 3C . At block 804, the control circuit system 112 determines the selected amperage (e.g., Figure 4 For example, the control circuit system 112 may determine whether the selected amperage is within the preferred amperage range based on the selected predetermined relationship. Figure 3A The corresponding preferred range 304, Figure 3B The corresponding preferred range of 322 or Figure 3C , or within any other range stored as a preferred range or optimal range.

[0128] If the selected amperage is not within the preferred range (block 804), then at block 806, the control circuitry 112 determines whether the selected amperage is within the allowable amperage range. For example, the control circuitry 112 may determine whether the selected amperage is within the allowable amperage range based on the selected predetermined relationship. Figure 3A The corresponding acceptable or restricted ranges 306, 308, Figure 3B The corresponding acceptable or restricted ranges 324, 326 or Figure 3C 346 , 348 , or within any other range stored as an allowable or acceptable range for the power conversion circuitry 110 implementation.

[0129] If the selected amperage is within the preferred amperage range (box 804), or the selected frequency is within the allowable frequency range (box 806), then at box 808, the control circuit system 112 determines that the selected frequency is acceptable, or determines that the operator will be allowed to use the selected frequency and amperage to perform welding operations.

[0130] Conversely, if the selected frequency is neither within the preferred frequency range (box 804) nor within the allowable frequency range (box 806), then at box 810, the control circuit system 112 determines that the selected frequency is unacceptable, or determines that the operator will not be permitted to perform a welding operation using the selected frequency and amperage.

[0131] After determining whether the selected frequency is acceptable (block 808) or unacceptable (block 810), the example instructions 800 ends and returns control to Figure 4 Frame 714.

[0132] Fig. 9 is a flow chart showing the Figure 1 The example machine readable instructions 900 executed by the welding-type power supply 102 are used to control the interface to output an indication of the selected amperage relative to the determined range based on one or more predetermined relationships. The example instructions 900 can be stored in the storage device 123 and / or the memory 124 and executed by the processor(s) 120. Figure 2A200 to discuss the instructions 900. However, blocks 902 to 916 may be Figure 1 The example remote interface 104 is implemented.

[0133] At block 902, the control circuitry 112 determines an AC or DC pulse frequency parameter of the welding-type power to be output by the power conversion circuitry 110. For example, the control circuitry 112 may receive a selection of a frequency via the knob 212 of the user interface 200. The frequency parameter may be a number of pulses per second (e.g., for DC pulse operation) or a number of cycles per second (e.g., for AC operation).

[0134] At block 904, the control circuitry 112 determines an amperage range based on the frequency. For example, the control circuitry 112 may determine the amperage range based on a predetermined relationship corresponding to one or more welding parameters, such as pulse peak current time, pulse peak current percentage, pulse background current time, pulse background current percentage, AC waveform type, or welding circuit inductance. The amperage parameter may be a current set point, an average current, a root mean square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current, and / or any other current.

[0135] The determined amperage range may be selected from one or more sub-ranges, such as a preferred range, an acceptable range, and / or a range where performance is limited, such as Figure 3A The range is 304 to 308, Figure 3B The range is 322 to 326 and Figure 3C The range 344 to 348 of FIG. In some examples, the determined amperage range is limited to the preferred range specified in table 126. In other examples, the determined amperage range may include an acceptable range, or include an acceptable range and a range where performance is limited.

[0136] At block 906, the control circuitry 112 determines whether a selection of amperage has been received. This may be done via a method such as Figure 2A and / or Figure 2B The control circuit system 112 may receive an example input for selecting an amperage by using an input device 115, 135 such as a knob 212. If an amperage selection has been received (block 906), then at block 908, the control circuit system 112 compares the selected amperage with the determined amperage range.

[0137] At block 910, the control circuitry 112 outputs an indication of the selected amperage relative to the determined amperage range. For example, the control circuitry 112 may output Figure 2A Graphics 214, Figure 2BAn indication graphic 258 and / or textual description 260, and / or any other indication (eg, message, alert, alarm, notification, etc.) representing a comparison of the selected amperage value with the determined amperage range.

[0138] At block 912, the control circuit system 112 determines whether the selected amperage is within the determined amperage range. If the selected amperage is not within the determined amperage range (block 912), at block 914, the control circuit system 112 outputs (e.g., via the user interface 114) a notification that the selected amperage is outside the determined amperage range. The notification may be in addition to or implemented into the indication of block 910. Conversely, if the selected amperage is within the determined amperage range (block 912), at block 916, the control circuit system 112 sets the amperage of the output waveform to the selected amperage.

[0139] If an amperage selection has not been made (block 906), then after the notification is output (block 914), or after the amperage is set (block 916), at block 918, the control circuit system 112 determines whether welding is valid. For example, the control circuit system 112 can determine whether welding current is flowing or whether there is an output voltage corresponding to the arc. If welding is valid (block 918), at block 920, the control circuit system 112 controls the power conversion circuit system 110 to output welding-type power using the set amperage. Control repeats back to block 918 to continue welding. If welding is invalid (block 918), control returns to block 902.

[0140] The present method and system may be implemented in hardware, software, and / or a combination of hardware and software. Typical combinations of hardware and software may include one or more application specific integrated circuits and / or chips. Some embodiments may include a non-transitory machine-readable (e.g., computer-readable) medium (e.g., flash memory, optical disk, magnetic storage disk, etc.) having one or more lines of code executable by a machine stored thereon, thereby causing the machine to perform 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 exclude propagating signals.

[0141] As used herein, the terms "circuit" and "circuitry" refer to physical electronic components (i.e., hardware) and any software and / or firmware ("code") that can configure hardware, be executed by hardware, and / or otherwise be associated with hardware. As used herein, for example, a specific processor and memory can constitute a first "circuit" when executing the first one or more lines of code, and can constitute a second "circuit" when executing the second one or more lines of code. As used herein, "and / or" refers to any one or more of the multiple items connected by "and / or" in the list. For example, "x and / or y" refers to any element in the three-element set {(x), (y), (x, y)}. In other words, "x and / or y" refers to "one or two of x and y". As another example, "x, y and / or z" refers to any element in the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, "x, y and / or z" refers to "one or more of x, y and z". As used herein, the term "exemplary" means serving as a non-limiting example, instance, or illustration. As used herein, the terms "eg" and "for example" set forth a list of one or more non-limiting examples, instances, or illustrations. As used herein, a circuit system is "operable" to perform a function when the circuit system includes the necessary hardware and code (if necessary) to perform the function, regardless of whether the performance of the function is disabled or not enabled (e.g., by a user-configurable setting, a factory adjustment, etc.).

[0142] Although the present method and / or system has been described with reference to certain embodiments, it will be appreciated by those skilled in the art that various changes may be made and may be replaced with equivalents without departing from the scope of the present method and / or system. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the present disclosure without departing from the scope of the present disclosure. For example, the frames and / or components of the disclosed examples may be combined, segmented, rearranged and / or otherwise modified. Therefore, the present method and / or system is not limited to the disclosed specific embodiments. Alternatively, the present method and / or system will include all embodiments that fall within the scope of the appended claims, either literally or according to the doctrine of equivalents.

Claims

1. A welding power supply, include: a power conversion circuit system configured to convert input power into welding-type power having at least one of an alternating current (AC) waveform or a pulsed waveform; an interface configured to receive an input representing a selected frequency of the AC waveform or the pulse waveform; and A control circuit system, the control circuit system being configured to: determining a value for an amperage parameter of the welding-type electrical power; determining a frequency range of the AC waveform or the pulse waveform based on a value of the amperage parameter; controlling the interface to output a representation of the selected frequency relative to an upper frequency limit and a lower frequency limit of the determined frequency range; responsive to a change in the selected frequency, controlling the interface to update a representation of the selected frequency relative to a representation of the upper frequency limit and the lower frequency limit of the frequency range; and The power conversion circuitry is controlled to output the welding-type power at the selected frequency and based on the amperage parameter.

2. The welding power supply according to claim 1, in, Each cycle of the AC waveform includes an electrode negative portion and an electrode positive portion.

3. The welding type power supply as claimed in claim 2, in, The amperage parameter includes at least one of: an average current, a root mean square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current.

4. The welding type power supply as claimed in claim 1, in, The interface is configured to receive a value for the amperage parameter.

5. The welding type power supply as claimed in claim 4, in, The control circuitry is configured to limit selection of the frequency via the interface based on at least one of the upper frequency limit or the lower frequency limit.

6. The welding-type power supply of claim 5, further comprising an output device configured to output a notification in response to determining that the difference between the selected frequency and the frequency limit is less than a threshold difference.

7. The welding type power supply according to claim 1, in, The control circuitry is configured to determine an inductance of a welding-type circuit, the power conversion circuitry being coupled to the welding-type circuit to output the welding-type power, wherein the control circuitry is configured to determine the frequency based on a value of the amperage parameter and the determined inductance.

8. The welding type power supply as claimed in claim 1, in, The control circuit system is configured to determine at least one of a pulse peak current time, a pulse peak current percentage, a pulse background current time, a pulse background current percentage, an AC waveform type, or a welding circuit inductance, wherein the control circuit system is configured to determine the frequency based on the value of the amperage parameter and at least one of: the pulse peak current time, the pulse peak current percentage, the pulse background current time, the pulse background current percentage, the AC waveform type, or the welding circuit inductance.

9. The welding type power supply as claimed in claim 1, in, Each cycle of the pulse waveform includes a peak current and a background current.

10. The welding type power supply according to claim 1, in, The control circuitry is configured to determine the frequency range of the AC waveform or the pulse waveform based on a selected one of a plurality of predetermined relationships between the frequency and a value of the amperage parameter.

11. A welding power supply, include: a power conversion circuit system configured to convert input power into welding-type power having at least one of an alternating current (AC) waveform or a pulsed waveform; an interface configured to receive an input representing a selected amperage; as well as A control circuit system, the control circuit system being configured to: determining a frequency of the AC waveform or the pulse waveform; determining an amperage range based on a frequency of the AC waveform or the pulse waveform; controlling the interface to output a representation of the selected amperage relative to an upper amperage limit and a lower amperage limit of the determined amperage range; responsive to a change in the selected amperage, controlling the interface to update a representation of the selected amperage relative to a representation of the upper amperage limit and the lower amperage limit of the determined amperage range; and The power conversion circuitry is controlled to output the welding-type power at the selected amperage and based on the frequency.

12. The welding type power supply according to claim 11, in, Each cycle of the AC waveform includes an electrode negative portion and an electrode positive portion.

13. The welding type power supply according to claim 12, in, The selected amperage includes at least one of an average current, a root mean square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current.

14. The welding type power supply according to claim 11, in, The interface is configured to receive a selection of the frequency.

15. The welding type power supply according to claim 14, in, The control circuitry is configured to limit selection of the amperage via the interface based on at least one of the upper amperage limit or the lower amperage limit.

16. The welding-type power supply of claim 15, further comprising an output device configured to output a notification in response to determining that a difference between the selected amperage and the amperage limit is less than a threshold difference.

17. The welding type power supply according to claim 11, in, The control circuitry is configured to determine an inductance of a welding-type circuit, the power conversion circuitry being coupled to the welding-type circuit to output the welding-type power, wherein the control circuitry is configured to determine the amperage based on the frequency and the determined inductance.

18. The welding type power supply according to claim 11, in, The control circuit system is configured to determine at least one of a pulse peak current time, a pulse peak current percentage, a pulse background current time, a pulse background current percentage, an AC waveform type, or a welding circuit inductance, wherein the control circuit system is configured to determine the amperage based on the frequency and at least one of: the pulse peak current time, the pulse peak current percentage, the pulse background current time, the pulse background current percentage, the AC waveform type, or the welding circuit inductance.

19. The welding type power supply according to claim 11, in, Each cycle of the pulse waveform includes a peak current and a background current.

20. The welding-type power supply according to claim 11, in, The control circuitry is configured to determine the amperage range of the AC waveform or the pulse waveform based on a selected one of a plurality of predetermined relationships between the frequency and the amperage parameter.

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