System and method for adaptively controlling welding wire preheating

Abstract

A welding type system (100) includes a power source (128) configured to control preheating of an electrode wire (138). A controller (102) is configured to receive a plurality of power values ​​corresponding to a power output of the power source (128), and to calculate an arc power value corresponding to an arc condition at the preheated electrode wire (138) based on a rate of change of the plurality of power values. A target power output value is determined based on the calculated arc power value, and the power output is adjusted based on the determined target power value. A method based on the same principle is also provided.

Description

[0001] This application is a divisional application of an invention patent application with an international application date of August 22, 2018, an international application number of PCT / US2018 / 047465, a national application number of 201880054547.6, and an invention name of “System and method for adaptively controlling preheating of welding wire”.

[0002] Related Applications

[0003] This international patent application claims priority to U.S. patent application serial number 15 / 690,563, entitled “SYSTEMS AND METHODS FOR ADAPTIVE CONTROL OF WIRE PREHEATING,” filed on August 30, 2017. The entire contents of U.S. patent application serial number 15 / 690,563 are incorporated herein by reference. Background Art

[0004] Welding is a process that has proven to be a cost effective joining method. Welding, at its core, is simply a way of joining two pieces of parent metal. Laser welding is a welding technique used to join pieces of metal through the use of lasers. The beam provides a concentrated heat source that enables precise control of heat input and high welding speeds, resulting in welds with low heat input and a small heat affected zone.

[0005] In various applications, filler metal may be required for different purposes, such as filling gaps, enhancing joints, covering substrate surfaces, building objects, or serving as a buffering medium. The filler material may enter the molten pool by pre-melting the coating or by feeding powder or welding wire into the molten pool. Wire feeders have several advantages, including almost full utilization of material, good misalignment tolerance, high cladding rate, cleaner working environment, safer operation, and low material cost. In some examples, the welding wire is provided by the welding tool and melted by the power focused on the workpiece, in other words, cold wire. In other examples, the welding wire is preheated to increase the temperature of the welding wire before being applied to the workpiece.

[0006] Welding with a heated wire can improve the stability and productivity of the cladding process. For example, preheating the wire can additionally release casting forces on the wire, which softens the wire to reduce recoil forces on the wire and torch. However, arcing conditions may occur using a preheating device. Laser energy can be used to melt the substrate surface to form a metallurgical bond. Laser welding techniques that utilize preheated wire, or "hot wire," make overall energy utilization more efficient and increase cladding rates, which can be up to three times as compared to using cold wire or powder.

[0007] Therefore, there is a need for a system that combines the advantages of preheated wire and laser welding techniques while reducing the likelihood of arcing conditions. Summary of the invention

[0008] The present disclosure generally relates to wire preheating systems, methods and apparatus for laser welding processes. More specifically, the present disclosure relates to a laser welding type system that uses a preheated electrode wire to perform a welding type operation. The system monitors and / or measures multiple values ​​associated with the preheated welding wire (e.g., temperature, voltage, current, resistance, impedance, enthalpy change, etc.). Based on the measured values, the system can identify and / or calculate at which point an arc condition may occur. The corresponding values ​​can be stored in a memory and used for comparison with values ​​measured during the welding type operation. If the measured values ​​reach or even tend toward one or more values ​​associated with the arc condition, the system can adjust one or more values ​​(e.g., power output for heating the welding wire, wire feed speed, etc.) to reduce the occurrence of arc conditions during the welding type operation.

[0009] In an example, a welding-type system includes a power source configured to preheat an electrode wire. A controller associated with the system is configured to receive a plurality of power values ​​corresponding to a power output of the power source. The controller calculates an arc power value corresponding to an arc condition at a preheated electrode wire based on a rate of change of the plurality of power values. A target power output value is determined based on the calculated arc power value. The controller then adjusts the power output based on the determined target power value.

[0010] In some examples, for a target power output level, the power output is regulated between a high threshold and a low threshold. The controller is configured to compare a first power value of the plurality of power values ​​to the high power threshold and the low power threshold and adjust the power output based on the comparison.

[0011] The controller is further configured to increase the power output if the first power output is below a low power threshold, and to decrease the power output if the first power output is above a high power threshold. The system includes a wire feeder, wherein the controller can adjust the wire feed speed based on a comparison of the first power value to a target power output value and a high threshold and a low threshold. In some examples, an arc condition occurs when at least a portion of the current is passing through a path that includes an arc.

[0012] In an example, a controller is configured to access a storage device including a plurality of arc power values ​​that associate rates of change of the plurality of power values ​​with corresponding arc conditions, and the controller is configured to identify an arc power value corresponding to the arc condition based on the rates of change of the plurality of power values.

[0013] The controller may interpolate a target power output value based on a rate of change of a plurality of power values ​​associated with corresponding arc condition values ​​stored in a memory device; and select a corresponding high power threshold and a low power threshold based on the interpolated target power output value. In an example, the plurality of power values ​​include voltage, current, resistance, enthalpy, or a combination thereof. Further, the controller may determine an enthalpy change associated with the electrode wire; and adjust the power output based in part on a comparison of the measured enthalpy change with a stored enthalpy change associated with the arc condition.

[0014] In another example, a welding-type system includes a power supply configured to resistively preheat an electrode wire. A wire feeder is used to drive the preheated electrode wire at a first wire feed speed for a welding-type operation. A sensor is configured to monitor an enthalpy change associated with the preheated electrode wire. Further, a controller receives a signal corresponding to an arc condition at the preheated electrode wire from the sensor, determines a change in enthalpy when the arc condition occurs at the preheated electrode wire based on the signal and the first wire feed speed, and adjusts the wire feed speed based on the determined change in enthalpy.

[0015] The sensor measures voltage, temperature, current, resistance, impedance, or a combination thereof. The controller is configured to adjust the power output of the power supply based on the enthalpy value, and is configured to adjust the power output of the power supply by a predetermined percentage of the power output. The controller adjusts the wire feed speed until the controller receives a signal from the sensor indicating that the arc condition is no longer detected. The controller may also adjust the wire feed speed by a predetermined percentage of the wire feed speed.

[0016] In yet another example, a method includes controlling power output to preheat an electrode wire through a controller of a power supply, receiving a signal value corresponding to an arc condition at the preheated electrode wire at the controller, identifying an arc power value corresponding to the arc condition through the controller, and adjusting the power output to be suitable for the preheated electrode wire at a predetermined interval below the arc power value through the controller.

[0017] The method may also include: accessing a storage device including multiple arc power values, wherein the multiple arc power values ​​associate the rate of change of the multiple power values ​​with the rate of change of the corresponding arc enthalpy values; and identifying the rate of change of the arc enthalpy value corresponding to the arc condition based on the rate of change of the multiple power values.

[0018] In some examples, the method stores a signal value corresponding to the arc condition and an arc power value in a storage device, the storage device including a plurality of values ​​associating the signal value with a corresponding arc enthalpy value. Additionally, the method calculates a power threshold based on a rate of change of the arc enthalpy value. In some examples, an arc condition occurs when at least a portion of the current is passing through a path that includes an arc. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 An exemplary laser welding system according to aspects of the present disclosure is shown.

[0020] Figure 2 It means that according to various aspects of the present disclosure, Figure 1 A flow chart of an exemplary method of a laser welding system.

[0021] 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

[0022] The present disclosure relates to a laser welding system that employs a continuously fed preheated electrode wire while reducing the occurrence of arc conditions. Specifically, the welding wire is resistively preheated (e.g., to a temperature just below the melting temperature of the welding wire) and then fed into a weld pool generated by a high-density energy beam. The system is configured to monitor multiple power values ​​and calculate when an arc condition will occur. The system is configured to store and update power values ​​corresponding to arc conditions. In this way, the system is able to identify when an arc condition is likely to occur based on historical information and adjust the characteristics of the system to prevent the occurrence of an arc condition.

[0023] The exemplary systems and methods disclosed herein employ a laser welding system to generate (i.e., one or more) laser beams and focus the laser beams to a focal position on a workpiece. The focal point corresponds to the contact point of the electrode wire where a weld pool is being formed. For example, power from the laser beam is used together with preheat energy to melt the electrode wire during the welding operation. The power required by the laser beam to melt the electrode is at least partially determined by the preheat level of the electrode wire.

[0024] In conventional systems, the user selects a wire feed speed and then needs to enter a corresponding power output value for a particular welding operation. If the power output to the associated wire heater is too high, an arc condition may occur. Additionally or alternatively, if the power output is too low, the welding operation may result in wire breakage.

[0025] The welding system described herein is capable of measuring multiple power values ​​(e.g., voltage, current, resistance, impedance, enthalpy, temperature, etc.) during one or more welding operations and calculating one or more output thresholds corresponding to arc conditions. The system records the output values ​​and the calculated output thresholds and adjusts or regulates the system output to avoid arc conditions. The controller is also capable of recording the power output values ​​associated with each welding operation and is capable of compensating for changes in the system identified during operation, such as contact tip wear, etc.

[0026] Compared to conventional devices, the welding system described herein does not require a user to identify and set a power output value (e.g., current, voltage, enthalpy, temperature, etc.) corresponding to a target power output value or adjustment point. Specifically, the welding system is configured to detect whether an arc condition exists and adjust accordingly. The system is configured to adjust the power output and measure one or more characteristics of the output to identify a threshold when an arc condition occurs. The system will then adjust the power output based on the measurement results.

[0027] In some examples, the user can adjust and / or override the desired output level or regulation point based on the measured output value corresponding to the identified arc condition. In addition, the welding system "learns" which power output values ​​correspond to the regulation points and updates the stored values ​​based on the feedback information.

[0028] Advantageously, the system is capable of operating with any wire type without requiring separate welding protocols for different types. In addition, the preheat threshold can be optimized based on historical information, including power output parameters, wire type, wire feed speed, etc. As described herein, the system is also configured to adapt to changes in the welding process, such as contact tip wear.

[0029] Compared to cold wire systems, preheating the electrode wire enables the system to increase the cladding rate during the welding process and reduce the laser power required to form the weld. In addition, the preheating method used for the welding wire is independent of the base material or weld pool conditions, providing a very stable process.

[0030] In order to promote an understanding of the principles of the claimed technology and present its best mode of operation currently understood, reference will now be made to the examples illustrated in the drawings and specific language will be used to describe these examples. However, it should be understood that no limitation of the scope of the claimed technology is intended thereby, and these changes and further modifications in the illustrated devices and these further applications of the principles of the claimed technology illustrated are considered to be what would normally occur to one skilled in the art to which the claimed technology relates.

[0031] As used herein, the word "exemplary" means used as an example, instance, or example. The examples described herein are not limiting, but merely exemplary. It should be understood that the described examples are not necessarily to be interpreted as being preferred or advantageous over other examples. In addition, the term "example" does not require that all examples of the present disclosure include the discussed features, advantages, or modes of operation.

[0032] As used herein, a wire-feed welding system refers to a system capable of performing welding (e.g., gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), etc.), brazing, cladding, surface hardening and / or other processes, wherein the filler metal is provided by a welding wire that is fed into a work position (e.g., an arc or weld pool).

[0033] As used herein, a welding-type power supply refers to any device that is capable of powering welding, cladding, plasma cutting, induction heating, laser (including laser welding and laser cladding), carbon arc cutting or gouging and / or resistive preheating when power is applied thereto, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuit systems and other auxiliary circuit systems associated therewith.

[0034] As used herein, preheating refers to heating the electrode wire before the welding arc and / or electrode wire is deposited in the travel path.

[0035] Some disclosed examples describe current being conducted "from" and / or "to" locations in a circuit and / or power supply. Similarly, some disclosed examples describe current being "provided" via one or more paths, which may include one or more conductive or partially conductive elements. The terms "from," "to," and "provided" used to describe the conduction of current do not require a direction or polarity of the current. Rather, for a given circuit, these currents may be conducted in either direction or have either polarity, even if exemplary current polarities or directions are provided or shown.

[0036] Figure 1 A functional diagram of an exemplary laser welding system 100 is shown, which uses a laser welding control 126 to control a laser welder 122 to perform a welding process through a laser welding torch 124. A continuously fed electrode wire 138 is driven by a wire feeder 130 to a workpiece 140 and is preheated by a wire heater 136. A power source 128 can provide power to the wire feeder 130, the wire heater 136, and the laser welder 122. Additionally or alternatively, the laser welder 122 can be powered by another power source to provide laser power to the welding wire 138.

[0037] As shown, the wire feeder 130 includes a spool 132 to hold a coiled electrode wire 138. Rollers 134 drive the welding wire 138 from the spool 132 to the workpiece 140. The laser welder 122 provides laser power 144 focused on the position of the workpiece 140 to produce a molten pool 142 (e.g., a molten pool). When the welding wire 138 is introduced into the molten pool 142, the welding wire 138 melts and is used in a welding process (e.g., additive manufacturing, welding and / or brazing). In some welding environments, the workpiece 140 is configured to be connected to the power source 128 via a return cable (e.g., a ground cable, via an arc sensing fixture, etc.).

[0038] In an example, the wire heater 136 is configured to pass an electric current through a portion of the welding wire 138 to resistively heat the welding wire 138, thereby increasing the thermal value (e.g., enthalpy, temperature, etc.) of the welding wire 138. In this way, the welding wire 138 is preheated before contacting the workpiece 140. Therefore, the amount of laser power required to melt the preheated welding wire 138 (e.g., through the molten pool) is reduced.

[0039] The system 100 includes a controller 102 to control the functions of the system 100. For example, the controller 102 can send and receive information to and from a power source 128, a wire feeder 130, a wire heater 136, and a welding control 126 of a laser welder 122. The controller 102 is configured to connect to a welding-type tool such as a laser torch 124 via a cable and / or a control arm to transmit power, send and / or receive information, and / or control the movement of the laser welder 122.

[0040] The controller 102 may include one or more components, such as a display 114, a processor 116, a sensor 118, an interface 120, and a memory 104. The memory 104 may include an instruction set 112 to direct the controller 102, and a record (e.g., a list, a matrix, etc.) of one or more values ​​(e.g., an arc condition value 106, a power value 108, and an enthalpy value 110).

[0041] The sensor 118 (e.g., one or more sensors) can monitor and / or measure one or more characteristics of the system 100. In some examples, the sensor 118 monitors the output (e.g., heat, enthalpy, current, voltage, etc.) of the wire heater 136 and the wire feed speed of the wire feeder 132. The sensor 118 can be configured to provide the acquired information to the controller 102, which can adjust one or more variables of the system 100 in response thereto, as described herein.

[0042] In the exemplary welding system 100, the sensor 118 can be configured to measure values ​​associated with the power output of the wire heater 138, such as preheat current, preheat power, preheat enthalpy or heat content, and / or preheat circuit impedance. The controller 102 monitors heating anomalies by comparing the measured values ​​to expected values, by evaluating the time derivative and / or integral of the measured values, and / or by statistical analysis (e.g., mean, standard deviation, root mean square (RMS) value, minimum, maximum, etc.).

[0043] However, during the welding process, an arc condition may occur along the wire feed path. An arc condition occurs when at least a portion of the current is passing through a path that includes an arc. For example, an arc condition may occur when the preheated welding wire 138 is cut or otherwise damaged (e.g., damaging the welding wire 138) along the wire feed path, thereby causing an arc.

[0044] In some cases, arcing conditions may occur because the preheating power output is too high for a particular welding process. For example, for a particular welding process and environment, the power output value (e.g., voltage, current, resistance, impedance, enthalpy, temperature, etc.) of the preheating device should be set to an appropriate level for the particular operation. However, changes in the welding process (e.g., changes in wire feed speed, etc.) may disturb the balance between the variables of the welding process.

[0045] To avoid changes in one or more variables leading to an arc condition, the system 100 is configured to update a list (e.g., a matrix, a record, etc.) of values ​​106-110 that associate an arc condition with a power output variable and a wire feed speed. The system 100 calculates and / or identifies when an arc condition is occurring or will occur based on a comparison of a measured value with a stored value. Based on a comparison of the preheat power output value and / or the wire feed speed, a target power output value or adjustment point can be identified, and the preheat power output value and / or the wire feed speed can be adjusted based on the target power output value to reduce an active or predicted arc condition. For example, if an arc condition is identified, the controller 102 can reduce the power output, such as by a predetermined amount or percentage.

[0046] As described herein, arc conditions may be predicted by measuring the rate of change of a power output value (e.g., voltage, current, resistance, impedance, enthalpy, temperature, etc.) or other characteristic of the system 100. Based on the rate of change, the controller 102 may adjust parameters of the system 100, such as preheat power, wire feed speed, etc. In an example, the feedback signal may represent a change in a measured parameter (e.g., voltage) between the contact tip and the workpiece 140.

[0047] In some examples, the controller 102 can perform a calibration routine by increasing the power output value until an arc condition occurs (e.g., a voltage spike is detected) or to a point when the measured value predicts that an arc condition will occur. Thus, the controller 102 can identify a target output power value based on information associated with the arc condition and store the value corresponding to the arc condition in the memory 104 for subsequent reference.

[0048] In an example, an arc fixture can be used to identify an arc condition. For example, the arc fixture can be configured to begin conducting current when an arc occurs or a short time before an arc occurs. The current can be measured and the information sent to the controller 102, which can identify a power output value associated with the arc condition, as described herein.

[0049] Additionally or alternatively, the controller 102 can identify a gradual change in power output value corresponding to wire degradation (e.g., associated with contact tip wear) that may result in an arc condition. The controller 1102 can identify the rate of change and increase the output power to compensate (e.g., by a predetermined amount, percentage, etc.).

[0050] In an example, the sensor 118 is an enthalpy measurement circuit configured to determine an enthalpy change associated with the welding wire 138. The exemplary measurement circuit can determine the enthalpy change based on a measured preheat current and / or voltage, and / or a voltage drop across a preheat portion of the electrode. The controller 102 receives a signal from the sensor 118 and controls the preheat current from the wire heater 138 based on the determined enthalpy change and a target enthalpy value to be applied to the welding wire 138.

[0051] In some examples, the controller 102 controls the preheat power level and the welding laser power level based on the target power output value, and modifies the welding laser power level in response to a user change to the preheat level. Additionally or alternatively, the preheat level and / or the welding laser power level can be specified by the user based on a target heat input, a target preheat power level, and / or a target ratio between the preheat power and the welding laser power.

[0052] The system 100 may include a user interface 120 connected to the controller 102. The user interface 120 enables a user of the welding system 130 to adjust the preheat level or provide additional or alternative instructions associated with the preheat level (e.g., welding type process, wire feed speed, electrode type, etc.). The controller 102 receives the instruction (e.g., preheat level or penetration level) selected through the interface 120 and controls the power supply 128 to change the preheat level. The controller 102 can also control the system 100 to adjust one or more aspects of the laser welding power based on the selected preheat level to improve performance at the selected preheat level. For example, the controller 102 is configured to control the preheat power based on at least one of a target total heat input to the weld, a travel speed, a target weld bead width, or a target penetration depth.

[0053] The controller 102 controls the system 100 using a preheat control loop that uses the voltage sensed by the arc sensing fixture and the current output by the system 100 to maintain a commanded power input, current input, voltage input, enthalpy, and / or impedance to the electrode wire 112. In some examples, the preheat control loop uses the error between the commanded preheat voltage and the voltage sensed by the fixture to identify a target power output level and adjust the preheat current, preheat voltage, and / or preheat power.

[0054] In some examples, additional and / or alternative preheating devices may be used. In some examples, the preheating device may be positioned along a wire feeding path leading to a processing head (e.g., near a wire feeder). In other examples, the preheating device may be integrated with the processing head of the laser welding system. For example, a wire heater may be included in the processing head of the laser welding system or located at another location along the wire feeding path to resistively heat the welding wire 112.

[0055] The laser welding system 100 can be an exemplary robot, such as the curved neck (i.e., gooseneck design) welding torch shown (or a handheld welding torch when under manual control), to which power is delivered by a power supply. In some examples, the welding laser 122 can generate laser power in the form of a constant continuous laser beam. Additionally or alternatively, the welding laser 122 generates a pulsed laser beam and / or any other desired laser profile. In some examples, the welding-type system 100 is configured to perform additive manufacturing, welding, and / or brazing operations.

[0056] The controller 102 receives input from a user interface 120, through which the user can select a process and / or input desired parameters (e.g., voltage, current, a specific pulsed or non-pulsed welding scheme, preheat energy or power, and the like). The user interface 120 can use any input device to receive input, such as through a keypad, keyboard, button, knob, touch screen, voice activation system, wireless device, remote controller, etc. In addition, the controller 102 controls the operating parameters based on the user's input and based on other current operating parameters. Specifically, the user interface 120 may include a display 150 to present, display, or indicate information to the operator. The controller 102 may also include a communication circuit system to transmit data to other devices in the system, such as a wire feeder 134. For example, in some cases, the power supply 128 communicates wirelessly with other welding devices in the welding system. In addition, in some cases, the power supply 128 uses a wired connection to communicate with other welding devices.

[0057] The controller 102 includes at least one controller or processor 116 that controls the operation of the laser welding system 100. The controller 102 receives and processes a plurality of inputs associated with the performance and requirements of the system. The processor 116 may include one or more microprocessors, such as one or more "general purpose" microprocessors, one or more special purpose microprocessors, and / or ASICs, FPGAs, and / or any other type of processing device. For example, the processor 116 may include one or more digital signal processors (DSPs).

[0058] The storage device 104 may include volatile memory, such as random access memory (RAM), and / or non-volatile memory, such as read-only memory (ROM), flash memory, a hard drive, and / or any other suitable optical, magnetic, and / or solid-state storage media) and / or combinations thereof. The storage device 104 may store a variety of information and may be used for a variety of purposes. For example, the storage device 104 may store processor-executable instructions 112 (e.g., firmware or software) for execution by the processor 116. In addition, one or more control schemes for various welding processes, along with associated settings and parameters, may be stored in the storage device 104 along with code configured to provide specific outputs (e.g., initiate wire feeding, enable gas flow, capture welding current data, detect short circuit parameters, determine spatter volume) or adjust specific operating parameters (e.g., voltage, current, enthalpy change, welding equipment settings, etc.) during operation.

[0059] Figure 2 2 is a flow chart representing an exemplary method 200, for example implemented as machine-readable instructions 112, which may be executed by the controller 102 to control a welding operation and / or preheating of the welding electrode wire 138. Figure 1 An exemplary method 200 is described.

[0060] At block 202, a controller (e.g., controller 102) associated with a power source (e.g., power source 128) controls power output (e.g., output to wire heater 136) to preheat an electrode wire (e.g., electrode wire 138). At block 204, the controller receives a signal value corresponding to an arc condition at the preheated electrode wire. At block 206, the controller compares the signal value to a plurality of stored arc power values ​​(e.g., power value 108, enthalpy value 110) corresponding to the arc condition (e.g., arc condition value 106). At block 208, the controller identifies the arc power value corresponding to the arc condition.

[0061] At block 210, the controller adjusts the power output to accommodate the preheated wire electrode. The amount of adjustment may be determined by the controller, such as based on a calculation, or at a predetermined interval (eg, a percentage) below the identified arc power value.

[0062] The laser welding system described herein has many advantages. When the described system, apparatus and method are used, the possibility of failure caused by arc conditions generated by resistive preheating devices is reduced.

[0063] 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 may include a first "circuit" when executing a first line or more lines of code, and may include a second "circuit" when executing a second line or more lines of code. As used herein, "and / or" refers to any one or more items connected by "and / or" in a list. For example, "x and / or y" refers to any element in a three-element set {(x), (y), (x, y)}. In other words, "x and / or y" refers to "one or both of x and y". As another example, "x, y and / or z" refers to any element in a 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.

[0064] As used herein, the terms "for example" and "such as" set forth a list of one or more non-limiting examples, instances, or instances.

[0065] Although the method and / or system of the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the method and / or system of the present disclosure. 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 system, frame or other components of the disclosed examples may be combined, divided, rearranged and / or otherwise modified. Therefore, the method and / or system of the present disclosure is not limited to the specific embodiments disclosed. On the contrary, the method and / or system of the present disclosure will include all embodiments that fall within the scope of the appended claims literally and according to the principle of equivalents.

Claims

1. A welding system comprising: a power source configured to preheat the electrode wire; as well as A controller, wherein the controller is configured as: determining a target power output value based on an enthalpy change associated with an arc condition of the preheated electrode wire; determining the enthalpy change associated with the preheated wire electrode; and A power output of the power supply is adjusted based in part on the determined target power output value and a comparison of the measured enthalpy change compared to a stored enthalpy change associated with an arc condition.

2. The system of claim 1, wherein the power output is regulated between a high power threshold and a low power threshold for the target power output value.

3. The system of claim 2, wherein the controller is configured to: comparing a first power value of a plurality of power values ​​corresponding to a power output of the power supply to the high power threshold and the low power threshold; and The power output is adjusted based on the comparison.

4. The system of claim 3, wherein the controller is configured to: If the first power value is below the low power threshold, increasing the power output; and If the first power value is above the high power threshold, the power output is reduced.

5. The system of claim 3 further comprising a wire feeder, the controller further configured to adjust a wire feed speed based on a comparison of the first power value with the target power output value and the high power threshold and the low power threshold.

6. The system of claim 1, wherein the arc condition occurs when at least a portion of the current is passing through a path that includes an arc.

7. The system of claim 1, wherein the controller is configured to: accessing a memory device including a plurality of arc power values ​​correlating rates of change of a plurality of power values ​​corresponding to a power output of the power supply with corresponding arc conditions; and An arc power value corresponding to an arc condition is identified based on the rate of change of the plurality of power values.

8. The system of claim 3, wherein the controller is configured to: interpolating the target power output value based at least in part on rates of change of the plurality of power values ​​associated with corresponding arc condition values ​​stored in a memory device; and A corresponding high power threshold and a low power threshold are selected based on the interpolated target power output value.

9. The system of claim 7, wherein the plurality of power values ​​comprises voltage, current, resistance, enthalpy, or a combination thereof.

10. A welding system comprising: A laser welder that performs a laser welding type operation by means of a laser welding torch; a power source configured to resistively preheat the electrode wire; a wire feeder for driving the preheated electrode wire at a wire feeding speed for the laser welding type operation; a sensor configured to monitor an enthalpy change associated with the preheated electrode wire; as well as A controller, wherein the controller is configured as: determining a change in enthalpy when an arc condition occurs at the preheated wire electrode based on the signal from the sensor and the wire feed speed; and The wire feed speed is adjusted based on the determined change in the enthalpy value.

11. The system of claim 10, further comprising a second sensor configured to measure voltage, temperature, current, resistance, impedance, or a combination thereof.

12. The system of claim 10, wherein the controller is further configured to adjust a power output of the power supply based on the enthalpy value.

13. The system of claim 12, wherein the controller is further configured to adjust the power output of the power supply by a predetermined percentage of the power output.

14. The system of claim 10, wherein the controller is further configured to adjust the wire feed speed until the controller receives a signal from the sensor indicating that the arc condition is no longer detected.

15. The system of claim 14, wherein the controller is further configured to adjust the wire feed speed by a predetermined percentage of the wire feed speed.

16. A method of performing a laser welding type operation comprising: Controlling the power output through a power supply controller to preheat the electrode wire; identifying, by the controller, an arc power value corresponding to a rate of change of an arc enthalpy value in response to an arc condition of the electrode wire; accessing a memory device including a plurality of arc power values ​​that correlate rates of change of the plurality of power values ​​with rates of change of corresponding arc enthalpy values; identifying a rate of change of an arc enthalpy value corresponding to the arc condition based on the rate of change of the plurality of power values; receiving, at the controller, a signal value corresponding to an arc condition at the preheated electrode wire; identifying, by the controller, the arc power value corresponding to the arc condition based at least in part on the signal value; storing the signal value corresponding to the arc condition and the arc power value in a storage device, the storage device including a plurality of values ​​associating signal values ​​with corresponding arc enthalpy values; as well as The power output is adjusted by the controller at a predetermined interval below the arc power value to be suitable for the preheated electrode wire.

17. The method of claim 16, further comprising calculating a power threshold based on a rate of change of the arc enthalpy value.

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