Welding power supply with wire preheating system

Abstract

An example welding power supply includes: a power conversion circuit system configured to convert input power into welding wire preheating power and output the welding wire preheating power to a preheating system; and a control circuit system configured to control the power conversion circuit system based on a temperature model to preheat the electrode wire to a target temperature via the preheating system.

Description

Background Art

[0001] The present disclosure relates generally to welding, and more particularly to methods and apparatus for converting welding-type power into welding-type power and resistance preheating power.

[0002] Welding is an increasingly common process across all industries. Welding, at its core, is a process of joining two pieces of metal. A wide variety of welding systems and welding control solutions have been implemented for various applications. In continuous welding operations, metal inert gas (MIG) welding and submerged arc welding (SAW) techniques allow for the formation of a continuous weld bead by feeding a wire electrode shielded by an inert gas from a welding torch and / or through a flux. This wire feeding system can be used with other welding systems, such as tungsten inert gas (TIG) welding. Power is applied to the wire, and an electrical circuit is completed through the workpiece to maintain the welding arc, melting the wire electrode and workpiece to form the desired weld. Summary of the Invention

[0003] There is disclosed, substantially as shown by and described in conjunction with at least one of the figures, a method and apparatus for providing welding-type power and preheating power as more fully set forth in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1A An example welding system according to aspects of the present disclosure is presented that includes a welding power supply configured to convert input power into welding power and preheating power.

[0005] Figure 1B Another example welding system according to aspects of the present disclosure is presented that includes a welding power supply configured to convert input power into welding power and a preheating power supply configured to convert the input power into preheating power.

[0006] Figure 2 yes Figure 1B A block diagram of an example implementation of a power supply.

[0007] Figure 3 An example user interface is shown that can be used to input electrode wire characteristics to determine a target temperature.

[0008] Figure 4 is a table representing an example database for storing target temperatures and / or resistivities associated with welding wire types.

[0009] Figure 5 is a flowchart representing example machine-readable instructions that may be executed by Figure 1A 、 Figure 1B and / or Figure 2An example power supply is implemented to output welding power and preheating power.

[0010] Figure 6 is a flowchart representing example machine-readable instructions that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 An example power supply is implemented to determine material properties of a wire electrode to be preheated.

[0011] Figure 7 is a flowchart representing example machine-readable instructions that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 An example power supply is executed to determine(s) pre-heating process parameters for heating an electrode wire to a target temperature.

[0012] Figure 8 is a flowchart representing example machine-readable instructions that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 An example power supply is implemented to control the power conversion circuit system to output wire preheating power.

[0013] The accompanying drawings are not necessarily drawn to scale. Where appropriate, similar or identical reference numbers are used to designate similar or identical components. DETAILED DESCRIPTION

[0014] For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the examples shown in the drawings, and specific language will be used to describe these examples. It should be understood, however, that this disclosure is not intended to limit the scope of the claims. Modifications of the illustrated examples and such further applications of the principles of the present disclosure illustrated herein are considered as would normally occur to one skilled in the art to which this disclosure relates.

[0015] For an electrode wire with given material properties (e.g., resistivity, density, specific heat capacity, etc.), a relationship between the final preheat temperature and the heating energy input can be defined. This relationship can be determined using the target wire temperature, process parameters, and material properties, and / or can be determined empirically by measuring the wire temperature using contact methods and / or reliable non-contact methods. An additional relationship exists between the final preheat temperature, preheat current, wire feed speed, and the square of the wire area. This relationship will compensate for variations in wire diameter, wire feed speed, and / or preheat distance, as the heating energy input varies depending on the mass to be heated, the resistance of the wire segment to be heated, and the preheat time.

[0016] The disclosed example systems and methods use a temperature model involving the relationships discussed above to preheat the electrode wire to a target temperature without requiring measurement of the temperature of the preheated wire. Measuring the temperature of the preheated wire within a welding torch can be difficult due to the configuration and / or geometry of the welding torch and the proximity of the preheated wire to the welding arc. Therefore, the disclosed example systems and methods allow for accurate and reliable preheat temperature control without requiring torch modifications. Furthermore, the disclosed example systems and methods can be readily adapted to many different types of preheat welding systems including different torches and / or power supplies.

[0017] The disclosed example systems and methods enable welding process developers to accurately target a defined preheat temperature without having to determine corresponding preheat process parameters, which can reduce welding process development time. Additionally or alternatively, welding process developers can use the disclosed systems and methods to more quickly understand how to balance preheat and weld energy for applications (e.g., welding hot-rolled materials), reduce heat input, reduce diffusible hydrogen in welds produced with cored wires (e.g., flux-cored wire, metal-cored wire), and / or regulate fume generation rates.

[0018] The disclosed example systems and methods use a temperature model (e.g., including the relationships discussed above) to define process parameters for controlling the preheating process during welding, such as wire feed speed, preheating distance, preheating current, and / or preheating voltage. Some examples integrate the temperature model into (multiple) preheating and / or welding control systems to control the preheating process to preheat to a target temperature defined by the system and / or user.

[0019] The disclosed example welding power supply includes: a power conversion circuit system configured to convert input power into wire preheating power and output the wire preheating power to a preheating system; and a control circuit system configured to control the power conversion circuit system based on a temperature model to preheat the electrode wire to a target temperature via the preheating system.

[0020] In some example power supplies, the control circuit system is configured to control the power conversion circuit system to heat the electrode wire to a target temperature without using a temperature sensor to measure the temperature of the preheated electrode wire. In some examples, the control circuit system is configured to control the power conversion circuit system by applying a temperature model based on one or more of the following: the initial temperature of the electrode wire, the cross-sectional area of ​​the electrode wire, the resistivity of the electrode wire, the density of the electrode wire, or the specific heat capacity of the electrode wire. In some such examples, the control circuit system is configured to control the power conversion circuit system by applying a temperature model based on the wire feed speed of the electrode wire. Some example power supplies further include a user interface configured to receive an input specifying one or more of the initial temperature of the electrode wire, the cross-sectional area of ​​the electrode wire, the resistivity of the electrode wire, the density of the electrode wire, or the specific heat capacity of the electrode wire.

[0021] In some example power supplies, the control circuit system is configured to determine one or more preheating parameters by accessing a storage device storing preheating parameters corresponding to a temperature model. In some examples, the temperature model is based on the following equation:

[0022]

[0023] Wherein, b is the initial temperature of the electrode wire, m is a constant based on one or more material properties of the electrode wire, I is the preheating current of the wire preheating power, A is the cross-sectional area of ​​the electrode wire, v is the wire feeding speed of the electrode wire, and temp is the target temperature.

[0024] The disclosed example power supply includes: a power conversion circuit system, which is configured to convert input power into welding wire preheating power and output the welding wire preheating power to the preheating circuit; and a control circuit system, which is configured to: determine the material properties of the electrode wire to be preheated via the welding wire preheating power, these material properties including one or more of the following: the initial temperature of the electrode wire, the cross-sectional area of ​​the electrode wire, the resistivity of the electrode wire, the density of the electrode wire, or the specific heat capacity of the electrode wire; determine the preheating process parameters for heating the electrode wire to the target temperature based on the material properties and the target temperature, the material properties and the preheating process parameters; and control the power conversion circuit system to output the welding wire preheating power based on the preheating process parameters for heating the electrode wire to the target temperature.

[0025] Some example power supplies further include one or more input devices, wherein the control circuitry is configured to determine at least one of the material properties based on inputs received via the one or more input devices. In some such examples, the inputs include an identification of a welding wire type. In some examples, the control circuitry is configured to determine the material property based on the identification of the welding wire type. In some examples, the control circuitry is configured to determine a welding wire diameter based on the inputs, or to automatically determine the wire diameter.

[0026] Some example welding power supplies further include one or more input devices, wherein the control circuit system is configured to determine the target temperature based on one or more inputs received via the one or more input devices. In some examples, the control circuit system is configured to determine the preheating current I of the wire preheating power based on the following equation as a first predetermined relationship:

[0027]

[0028] Wherein, b is the initial temperature of the wire electrode, m is a constant based on at least one material property of the wire electrode or based on the configuration of the preheating circuit, A is the cross-sectional area of ​​the wire electrode, v is the wire feed speed of the wire electrode, and temp is the target temperature.

[0029] In some example welding power supplies, the preheating circuit includes a first contact tip of a welding torch and a second contact tip of the welding torch. In some examples, the first predetermined relationship includes a second-order polynomial relating the wire temperature to a plurality of preheating process parameters, wherein the preheating process parameters include two or more of wire feed speed, preheating current, preheating voltage, preheating power, preheating resistance, preheating enthalpy, or preheating length.

[0030] In some examples, the control circuit system is configured to select a first predetermined relationship from a plurality of predetermined relationships. In some examples, the preheating process parameters include one or more of wire feed speed, preheating current, preheating voltage, preheating power, preheating resistance, preheating enthalpy, or preheating length.

[0031] In some example welding power supplies, the control circuitry is configured to control the power conversion circuitry to heat the wire electrode to a target temperature without using a temperature sensor to measure the temperature of the preheated wire electrode. In some examples, the control circuitry is configured to determine the target temperature to which the wire electrode is to be preheated.

[0032] 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 be associated with hardware in other ways. As used herein, for example, when executing a first set of one or more lines of code, a specific processor and memory may include a first "circuit", and when executing a second set of one or more lines of second code, a second "circuit" may be included. As used herein, "and / or" refers to any one or more of the multiple 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. As used herein, the terms "e.g.," and "for example," introduce a list of one or more examples, instances, or illustrations. As used herein, a circuit system is "operable" to perform a function whenever it includes the necessary hardware and code (if necessary) to perform the function, regardless of whether performance of the function is disabled or not enabled (e.g., by an operator-configurable setting, a factory adjustment, etc.).

[0033] As used herein, a wire-fed welding system refers to a system capable of performing welding (e.g., gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), submerged arc welding (SAW), etc.), brazing, cladding, hardfacing, and / or other processes in which filler metal is provided by a wire fed into a work location (e.g., an arc or weld pool).

[0034] As used herein, a welding power supply refers to any device capable of supplying power for welding, cladding, plasma cutting, induction heating, laser processing (including laser welding and laser cladding), carbon arc cutting or scraping, 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, and the like, as well as control circuit systems and other auxiliary circuit systems associated therewith. The terms "power supply" and "power supply" are used interchangeably herein.

[0035] As used herein, preheating refers to heating the wire electrode prior to the welding arc and / or deposition in its path of travel.

[0036] Some disclosed examples describe conducting current "from" and / or to some locations in a circuit and / or power supply. Similarly, some disclosed examples describe "providing" current via one or more paths, which may include one or more conductive elements or partially conductive elements. The terms "from," "to," and "providing" used to describe the conduction of current do not mandate the direction or polarity of the current. Rather, even if example current polarity or direction is provided or illustrated, for a given circuit, these currents can be conducted in either direction or have either polarity.

[0037] Figure 1A An example welding system 10 is shown that includes a welding power supply 12 configured to convert input power into welding power and preheating power. Figure 1A The example welding system 10 includes a welding power supply 12 and a preheating torch 14. The welding torch 14 can be a welding torch configured for any wire-feed welding process, such as metal arc welding (GMAW), flux-cored arc welding (FCAW), self-shielded FCAW, and / or submerged arc welding (SAW), based on the desired welding application.

[0038] The welding power supply 12 converts input power from the main power source 22 into one or both of output welding power and / or preheating power that is output to the welding torch 14. Figure 1A In the example of , the welding power source also supplies filler metal to the welding torch 14 which is configured for GMAW welding, FCAW welding, or SAW welding.

[0039] The welding power supply 12 is coupled to or includes a source of main power 22, such as an electrical grid or an engine-driven generator that supplies main power, which may be single-phase or three-phase AC power. For example, the welding power supply 12 may be an engine-driven welding power source that includes an engine and a generator that provide the main power 22 within the welding power supply 12. The welding power supply 12 may process the main power 22 to output welding-type power for output to the welding torch 14 via the torch cable 50.

[0040] The power conversion circuitry 30 converts main power (e.g., AC power) into welding-type power, either direct current (DC) or AC, and into preheating power. Example preheating power may include DC and / or AC current that, when conducted through a portion of the electrode wire 54, provides resistive heating or Joule heating. Additional examples of preheating power disclosed herein may include high-frequency AC current that provides inductive heating within the electrode wire 54, and / or power suitable for hot wire welding techniques, arc-based preheating (where the arc is used to apply heat to the wire prior to the welding arc), laser-based preheating, radiative heating, convection heating, and / or any other form of wire heating. The power conversion circuitry 30 may include circuit elements such as transformers, switches, boost converters, inverters, buck converters, half-bridge converters, full-bridge converters, forward converters, flyback converters, internal buses, bus capacitors, voltage and current sensors, and / or any other topology and / or circuitry to facilitate converting input power into welding power and preheating power and outputting the welding power and preheating power to the welding torch 14. Example implementations of power conversion circuitry 30 are disclosed in greater detail below.

[0041] The first and second portions of the input power can be divided by time (e.g., the first portion is used at a first time and the second portion is used at a second time) and / or divided as a portion of the total delivered power at a given time. The power conversion circuit system 30 outputs welding power to the welding circuit and outputs preheating power to the preheating circuit or other preheater. The welding circuit and the preheating circuit can be implemented using any combination of the welding torch 14, the welding accessory, and / or the power supply 12.

[0042] The power conversion circuitry 30 may include circuit elements, such as a boost converter. In some examples, the main power 22 received by the power conversion circuitry 30 is an AC voltage between approximately 110 V and 575 V, between approximately 110 V and 480 V, or between approximately 110 V and 240 V. As used with reference to input power, the term "approximately" may mean within 5 volts or within 10% of a desired voltage.

[0043] The power conversion circuitry 30 can be configured to convert input power into any conventional and / or future welding-type output. The example power conversion circuitry 30 can implement one or more controlled voltage control loops, one or more controlled current control loops, one or more controlled power control loops, one or more controlled enthalpy control loops, and / or one or more controlled resistance control loops to control the voltage and / or current output to the welding circuit and / or to the preheating circuit. As described in more detail below, the power conversion circuitry 30 can be implemented using one or more conversion circuits, such as a plurality of conversion circuits, wherein separate conversion circuits are used to generate each of the welding-type output and the preheating output.

[0044] In some examples, the power conversion circuitry 30 is configured to convert input power into a controlled waveform welding output, such as a pulse welding process or a short circuit welding process (eg, regulated metal deposition (RMD)). TM )). For example, RMD TM The welding process utilizes a controlled waveform welding output whose current waveform changes at specific points in time within the short circuit period.

[0045] The welding power supply 12 includes a control circuit system 32 and a user interface 34. The control circuit system 32 controls the operation of the welding power supply 12 and can receive input from the user interface 34, through which an operator can select a welding process (e.g., GMAW, FCAW, SAW) and enter desired input power parameters (e.g., voltage, current, a specific pulsed or non-pulsed welding protocol, etc.). The control circuit system 32 can be configured to receive and process a plurality of inputs regarding the performance and requirements of the system 10.

[0046] The control circuitry 32 includes one or more controllers and / or processors 36 that control the operation of the power supply 12. The control circuitry 32 receives and processes a plurality of inputs associated with the performance and requirements of the system. The processor(s) 36 may include one or more microprocessors, such as one or more "general purpose" microprocessors, one or more special purpose microprocessors and / or ASICS, one or more microcontrollers, and / or any other type of processing and / or logic device. For example, the control circuitry 32 may include one or more digital signal processors (DSPs). The control circuitry 32 may include circuitry such as relay circuitry, voltage and current sensing circuitry, power storage circuitry, and / or other circuitry, and is configured to sense the main power 22 received by the power supply 12.

[0047] The example control circuitry 32 includes one or more memory devices 38. The memory device(s) 38 may include volatile and / or non-volatile memory and / or storage devices, such as random access memory (RAM), read-only memory (ROM), flash memory, a hard drive, a solid-state storage device, and / or any other suitable optical, magnetic, and / or solid-state storage media. The memory device(s) 38 store 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 the posture (e.g., orientation) of the welding torch, the distance between the contact tip and the workpiece, voltage, current, welding device settings, and the like. The memory device 38 may store machine-executable instructions (e.g., firmware or software) for execution by the processor(s) 36. Additionally or alternatively, one or more control schemes for various welding processes, along with associated settings and parameters, may be stored in the memory device(s) 38 along with machine-executable instructions configured to provide specific outputs during operation (e.g., starting wire feed, allowing gas flow, capturing welding current data, detecting short circuit parameters, determining the amount of spatter).

[0048] The example user interface 34 enables control or adjustment of parameters of the welding system 10. The user interface 34 is coupled to the control circuitry 32 to facilitate an operator to select and adjust a welding process (e.g., pulsed, short circuit, FCAW) by selecting wire size, wire type, material, and gas parameters. The user interface 34 is coupled to the control circuitry 32 for controlling the voltage, amperage, power, enthalpy, resistance, wire feed speed, and arc length of the welding application. The user interface 34 can receive input using any input device (e.g., via a keypad, keyboard, buttons, touch screen, voice activated system, wireless device, etc.).

[0049] The user interface 34 may receive input specifying a wire material (e.g., steel, aluminum), wire type (e.g., solid, cored), wire diameter, gas type, and / or any other parameter. Upon receiving the input, the control circuitry 32 determines a welding output for the welding application. For example, the control circuitry 32 may determine a welding voltage, welding current, wire feed speed, inductance, welding pulse width, relative pulse amplitude, waveform, preheat voltage, preheat current, preheat pulse, preheat resistance, preheat energy input, and / or any other welding and / or preheating parameters for the welding process based at least in part on the input received via the user interface 34.

[0050] In some examples, the welding power supply 12 can include polarity reversal circuitry. When directed by the control circuitry 32, the polarity reversal circuitry reverses the polarity of the output welding power. For example, some welding processes (such as TIG welding) can achieve the desired weld when the electrode has a negative polarity (referred to as DC electrode negative) (DCEN). Other welding processes (such as stick welding or GMAW welding) can achieve the desired weld when the electrode has a positive polarity (referred to as DC electrode positive) (DCEP). When switching between TIG and GMAW welding processes, the polarity reversal circuitry can be configured to reverse the polarity from DCEN to DCEP.

[0051] Additionally or alternatively, the operator may simply connect the welding torch 14 to the power supply 12 without knowing the polarity (e.g., when the welding torch is located a significant distance from the power supply 12). The control circuitry 32 may instruct the polarity reversal circuitry to reverse the polarity in response to a signal received through the communication circuitry and / or based on a selected or determined welding process.

[0052] In some examples, the power supply 12 includes communication circuitry. For example, the communication circuitry can be configured to communicate with the welding torch 14, accessories, and / or other device(s) coupled to the power cable and / or communication port. The communication circuitry sends and receives command and / or feedback signals via the welding power cable used to supply welding-type power. Additionally or alternatively, the communication circuitry can communicate wirelessly with the welding torch 14 and / or other device(s).

[0053] For some welding processes (e.g., GMAW), a shielding gas is utilized during welding. Figure 1A In an example, the welding power supply 12 includes one or more gas control valves 46 configured to control the flow of gas from a gas source 48. The control circuit system 32 controls the gas control valves 46. The welding power supply 12 can be coupled to the one or more gas sources 48 because, for example, some welding processes may utilize a shielding gas that is different from other welding processes. In some examples, the welding power supply 12 is configured to supply gas and welding power and / or preheating power to the welding torch 14 via a combination torch cable 50. In other examples, the gas control valve 46 and the gas source 48 can be separate from the welding power supply 12. For example, the gas control valve 46 can be configured to be connected to the combination torch cable 50 via a connector.

[0054] The example power supply 12 includes a wire feed assembly 60 that supplies an electrode wire 54 to the welding torch 14 for welding operations. The wire feed assembly 60 includes components such as a wire spool 64 and a wire drive configured to provide power to a drive roller 68. The wire feed assembly 60 feeds the electrode wire 54 along a torch cable 50 to the welding torch 14. The welding output can be supplied via the torch cable 50 coupled to the welding torch 14 and / or the work cable 42 coupled to the workpiece 44. As disclosed in more detail below, the preheat output can be supplied to the welding torch 14 (or to another welding torch via a connection in the wire feed assembly 60), supplied to the welding torch 14 via one or more preheat power terminals, and / or supplied to a preheater within the wire feed assembly 60 or within the housing 86 of the welding power supply 12.

[0055] The example power supply 12 is coupled to a preheating GMAW torch 14 that is configured to supply gas, a wire electrode 54, and power to a welding application. As discussed in more detail below, the welding power supply 12 is configured to receive input power, convert a first portion of the input power into welding power, and output the welding power to a welding circuit, and convert a second portion of the input power into preheating power, and output the preheating power to a preheating circuit or other preheater.

[0056] The example welding torch 14 includes a first contact tip 18 and a second contact tip 20. A wire electrode 54 is fed from a wire feed assembly 60 to the welding torch 14 and through the contact tips 18, 20 to generate a welding arc 26 between the wire electrode 54 and a workpiece 44. The preheating circuit includes the first contact tip 18, the second contact tip 20, and a portion 56 of the wire electrode 54 located between the first contact tip 18 and the second contact tip 20. The example power supply 12 is further coupled to a work cable 42, which is coupled to the workpiece 44.

[0057] In operation, the electrode wire 54 passes through the second contact terminal 20 and the first contact terminal 18, between which the power conversion circuit system 30 outputs a preheating current to heat the electrode wire 54. Specifically, Figure 1A In the illustrated configuration, the preheating current enters the wire electrode 54 via the second contact tip 20 and exits via the first contact tip 18. However, the preheating current can be conducted in the opposite direction using AC and / or a combination of AC and DC. At the first contact tip 18, the welding current can also enter (or exit) the wire electrode 54.

[0058] The welding current is output by the power conversion circuitry 30, which derives preheating power and welding power from the main power source 22. The welding current flows between the wire electrode 54 and the workpiece 44, generating the welding arc 26. When the wire electrode 54 makes contact with the workpiece 44, or when an arc exists between the wire electrode 54 and the workpiece 44, the circuit is completed, and the welding current flows through the wire electrode 54, across the arc 26, across the metal workpiece(s) 44, and back to the power conversion circuitry 30 via the work cable 42. The welding current melts the parent metal of the wire electrode 54 and the workpiece(s) 44, thereby bonding the workpieces together as the melt solidifies. By preheating the wire electrode 54, the generated welding arc 26 can have significantly reduced arc energy. Generally speaking, the preheating current is proportional to the distance between the contact tips 18, 20 and the wire electrode 54.

[0059] During operation, the power conversion circuitry 30 establishes a preheating circuit to conduct a preheating current through the segment 56 of the electrode wire 54. The preheating current flows from the power conversion circuitry 30 to the second contact terminal 20 via the first conductor 70, through the segment 56 of the electrode wire 54 to the first contact terminal 18, and returns to the power conversion circuitry 30 via the second conductor 72 that connects the power conversion circuitry 30 to the first contact terminal 18. Either, both, or neither of the conductors 70, 72 can be combined with other cables and / or conduits. For example, the conductor 70 and / or the conductor 72 can be part of the cable 50. In other examples, the conductor 72 is included in the cable 50, and the conductor 70 is routed separately to the welding torch 14. To this end, the power supply 12 can include one to three terminals to which one or more cables can be physically connected to establish the preheating connection, the welding connection, and the working connection. For example, multiple connections can be implemented in a single terminal with appropriate insulation between the different connections.

[0060] exist Figure 1A In the example shown, the power supply 12 includes two terminals 74, 76 that are configured to output welding power to the contact tip 20 and the work cable 42. The conductor 72 couples the terminal 74 to the welding torch 14, which provides power from the conductor 72 to the contact tip 18. The work cable 42 couples the terminal 76 to the workpiece 44. The example terminals 74, 76 may have a specified polarity or may have a reversible polarity.

[0061] Because the preheating current path overlaps with the welding current path on the connection between the first contact terminal 18 and the power conversion circuit system 30 (e.g., via conductor 72), the cable 50 can achieve a more cost-effective single connection (e.g., a single cable) between the first contact terminal 18 and the power conversion circuit system 30 than providing separate connections for welding current to the first contact terminal 18 and preheating current to the first contact terminal 18.

[0062] The example power supply 12 includes a housing 86 within which the control circuitry 32, the power conversion circuitry 30, the wire feed assembly 60, the user interface 34, and / or the gas control valve 46 are enclosed. In examples where the power conversion circuitry 30 includes multiple power conversion circuits (e.g., a preheating power conversion circuit and a welding power conversion circuit), all of the power conversion circuits are included in the housing 86.

[0063] Figure 1B Another example welding system 100 is shown, which includes a welding power supply 110 configured to convert input power into welding power and a preheating power supply 108 configured to convert the input power into preheating power. The welding system 100 includes an example welding torch 14 having contact tips 18, 20. The system 100 further includes a wire electrode 54 fed from a wire spool 106, the preheating power supply 108, and the welding power supply 110. The system 100 is shown as generating a welding arc 26 between the wire electrode 54 and a workpiece 44 during operation.

[0064] exist Figure 1B In the example of FIG. 1 , the system 100 includes separate power supplies 108, 110 to provide welding power and preheating power to the welding torch 14, rather than Figure 1A A single power supply 12 in the example of FIG.

[0065] In operation, the electrode wire 54 passes from the wire spool 106 through the second contact end 20 and the first contact end 18, between which the preheating power supply 108 generates a preheating current to heat the electrode wire 54. Figure 1B In the configuration shown, preheat current enters the wire electrode 54 via the second contact terminal 20 and exits via the first contact terminal 18. The example preheat power supply 108 may implement a controlled voltage control loop or a controlled current control loop to control the voltage and / or current output to the preheat circuit.

[0066] At the first contact tip 18, welding current may also enter the wire electrode 114. The welding current is generated or otherwise provided by the welding power supply 110. The welding current flows between the wire electrode 54 and the workpiece 44, thereby generating the welding arc 26. When the wire electrode 54 makes contact with the target metal workpiece 106, or when an arc exists between the wire electrode 54 and the workpiece 44, the circuit is completed and the welding current flows through the wire electrode 54, across the arc 26, across the metal workpiece(s) 44, and back to the welding power supply 110. The welding current melts the parent metal of the wire electrode 54 and the workpiece(s) 44, thereby bonding the workpieces together as the melt solidifies. By preheating the wire electrode 54, the generated welding arc 26 can have significantly reduced arc energy. Generally, the preheating current is proportional to the distance between the contact tips 18, 20 and the wire electrode 54.

[0067] The welding current is generated or otherwise provided by the welding power supply 110, while the preheating current is generated or otherwise provided by the preheating power supply 108. The preheating power supply 108 and the welding power supply 110 may ultimately share a common power source (e.g., a common generator or line current connection), but the current from the common power source is converted, inverted, and / or regulated to produce two separate currents—the preheating current and the welding current. For example, a single power supply and associated inverter circuitry may be utilized to facilitate the preheating operation, in which case the three leads may extend from the single power source.

[0068] During operation, the system 100 establishes a welding circuit to conduct welding current from the welding power supply 110 to the first contact tip 18 and back to the power supply 110 via the welding arc 112, the workpiece 106, and the work lead 118. To enable connection between the welding power supply 110 and the first contact tip 18 and the workpiece 44, the welding power supply 110 includes terminals 120, 122 (e.g., a positive terminal and a negative terminal).

[0069] During operation, the preheating power supply establishes a preheating circuit to conduct a preheating current through the segment 56 of the wire electrode 54. To enable connection between the preheating power supply 108 and the contact tips 18, 20, the preheating power supply 108 includes terminals 128, 130. The preheating current flows from the preheating power supply 108 to the second contact tip 20, the segment 56 of the wire electrode 54, the first contact tip 18, and back to the preheating power supply 108 via a cable 132 that connects the terminal 120 of the welding power supply 110 to the terminal 130 of the preheating power supply 108.

[0070] Because the preheating current path overlaps with the welding current path at the connection between the first contact terminal 18 and the power supplies 108, 110, the cable 132 can implement a more cost-effective single connection (e.g., a single cable) between the first contact terminal 18 and the power supplies 108, 110 than providing separate connections for welding current to the first contact terminal 18 and preheating current to the first contact terminal 18. In other examples, the terminal 130 of the preheating power supply 108 is connected to the first contact terminal 18 via a separate path than the path between the first contact terminal 18 and the welding power supply 110.

[0071] like Figure 1B As shown, the example system 100 includes a wire feeder 134 that feeds the electrode wire 54 to the welding torch 14 using a wire drive 136. The electrode wire 54 exits the wire feeder 134 and travels through a wire liner 138.

[0072] Figure 2 yes Figure 1B 1 . The example power supplies 108, 110 power, control, and supply consumables to a welding application. In some examples, the power supplies 108, 110 supply input power directly to the welding torch 108. In the illustrated example, the power supplies 108, 110 are configured to supply power to a welding operation and / or a preheating operation. The example power supplies 108, 110 also provide power to a wire feeder to supply the electrode wire 54 to the welding torch 108 for various welding applications (e.g., GMAW welding, flux-cored arc welding (FCAW), SAW).

[0073] The power supply 108, 110 receives main power 208 (e.g., from the 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 and / or preheating devices according to the needs of the system. The main power 208 can be supplied from another location (e.g., the main power can be derived from the grid). The power supply 108, 110 includes a power conversion circuit system 210, which can include a transformer, rectifier, switch, etc. capable of converting AC input power into AC and / or DC output power as dictated by the needs of the system (e.g., a specific welding process and protocol). The power conversion circuit system 210 converts the input power (e.g., main power 208) into welding-type power based on a welding voltage setpoint and outputs the welding-type power via the welding circuit.

[0074] In some examples, the power conversion circuitry 210 is configured to convert the main power 208 into a welding-type power output and an auxiliary power output. However, in other examples, the power conversion circuitry 210 is adapted to convert only the main power into a welding power output, and a separate auxiliary converter is provided to convert the main power into auxiliary power. In some other examples, the power supplies 108, 110 receive the converted auxiliary power output directly from a wall outlet. The power supplies 108, 110 can employ any suitable power conversion system or mechanism to generate and supply welding power and auxiliary power.

[0075] The power supplies 108 and 110 include control circuitry 212 for controlling the operation of the power supplies 108 and 110. The power supplies 108 and 110 also include a user interface 214. The control circuitry 212 receives input from the user interface 214, through which a user can select a process and / or enter desired parameters (e.g., voltage, current, a specific pulsed or non-pulsed welding schedule, etc.). The user interface 214 can receive input using any input device (e.g., via a keypad, keyboard, buttons, touch screen, voice activation system, wireless device, etc.). In addition, the control circuitry 212 controls operating parameters based on the user input and other current operating parameters. Specifically, the user interface 214 can include a display 216 for presenting, displaying, or indicating information to the operator. The control circuitry 212 can also include interface circuitry for transmitting data to other devices in the system, such as a wire feeder. For example, in some cases, the power supplies 108 and 110 wirelessly communicate with other welding devices within the welding system. Further, in some cases, the power supplies 108, 110 communicate with other welding devices using a wired connection, such as by using a network interface controller (NIC) to transmit data over a network (e.g., Ethernet, 10baseT, 10base100, etc.). Figure 2 In the example of FIG, the control circuit system 212 communicates with the wire feeder via the welding circuit via the communication transceiver 218.

[0076] The control circuit system 212 includes at least one controller or processor 220 that controls the operation of the welding power supplies 108, 110. The control circuit system 212 receives and processes a plurality of inputs associated with the performance and requirements of the system. The processor 220 may include one or more microprocessors (e.g., 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 220 may include one or more digital signal processors (DSPs).

[0077] The example control circuit system 212 includes one or more storage devices 223 and one or more memory devices 224. The storage device(s) 223 (e.g., non-volatile storage devices) may include 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 223 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 the posture (e.g., orientation) of the welding torch, the distance between the contact tip and the workpiece, voltage, current, welding device settings, and the like.

[0078] The memory device 224 may include volatile memory (e.g., random access memory (RAM)) and / or non-volatile memory (e.g., read-only memory (ROM)). The memory device 224 and / or the storage device(s) 223 may store a variety of information and may be used for a variety of purposes. For example, the memory device 224 and / or the storage device(s) 223 may store processor-executable instructions 225 (e.g., firmware or software) for execution by the processor 220. Additionally, one or more control schemes for various welding processes, along with associated settings and parameters, may be stored in the storage device 223 and / or the memory device 224, along with code configured to provide specific outputs during operation (e.g., starting wire feed, allowing gas flow, capturing welding current data, detecting short circuit parameters, determining the amount of spatter).

[0079] In some examples, welding power flows from the power conversion circuitry 210 through a welding cable 226. The example welding cable 226 can be attached and detached from the welding post at each power supply 108, 110 (e.g., to facilitate replacement of the welding cable 226 in the event of wear or damage). In addition, in some examples, welding data is provided through the welding cable 226, such that welding power and welding data are provided and transmitted together through the welding cable 226. The communication transceiver 218 is communicatively coupled to the welding cable 226 to exchange (e.g., send / receive) data through the welding cable 226. The communication transceiver 218 can be implemented based on various types of power line communication methods and technologies. For example, the communication transceiver 218 can utilize IEEE Standard P1901.2 to provide data communication through the welding cable 226. In this manner, the welding cable 226 can be utilized to provide welding power from the power supplies 108, 110 to the wire feeder 134 and the welding torch 14. Additionally or alternatively, a welding cable 226 can be used to transmit and / or receive data communications to / from the wire feeder 134 and the welding torch 108. The communication transceiver 218 is communicatively coupled to the welding cable 226, for example, via a cable data coupler 227, to incorporate features of the welding cable 226, as described in more detail below. The cable data coupler 227 can be, for example, a voltage sensor or a current sensor.

[0080] In some examples, the power supplies 108 , 110 include or are implemented in a wire feeder.

[0081] The example communication transceiver 218 includes a receiver circuit 221 and a transmitter circuit 222. Generally speaking, the receiver circuit 221 receives data sent by the wire feeder via the welding cable 226, and the transmitter circuit 222 transmits the data to the wire feeder via the welding cable 226. As described in more detail below, the communication transceiver 218 enables remote configuration of the power supply 108, 110 from the location of the wire feeder and / or enables the power supply 108, 110 to use welding voltage feedback information transmitted by the wire feeder 134 to compensate for the welding voltage. In some examples, the receiver circuit 221 receives (multiple) communications via the welding circuit while welding current is flowing through the welding circuit (e.g., during welding-type operation) and / or after welding current has stopped flowing through the welding circuit (e.g., after welding-type operation). Examples of such communications include welding voltage feedback information measured at a device (e.g., a wire feeder) remote from the power supply 108, 110 while welding current is flowing through the welding circuit.

[0082] An example implementation of the communication transceiver 218 is described in US Patent No. 9,012,807. The entire contents of US Patent No. 9,012,807 are incorporated herein by reference. However, other implementations of the communication transceiver 218 may be used.

[0083] The example wire feeder 134 also includes a communication transceiver 219 , which may be similar or identical in structure and / or function to the communication transceiver 218 .

[0084] In some examples, the gas supply 228 provides shielding gas, such as argon, helium, carbon dioxide, etc., depending on the welding application. The shielding gas flows to the valve 230, which controls the gas flow and, if necessary, can be selected to allow adjustment or regulation of the amount of gas supplied to the welding application. The valve 230 can be opened, closed, or otherwise operated by the control circuit system 212 to allow, prohibit, or control the flow of gas (e.g., shielding gas) through the valve 230. The shielding gas leaves the valve 230 and flows through the cable 232 (which, in some embodiments, can be combined with a welding power output) to the wire feeder, which provides shielding gas for the welding application. In some examples, the power supply 108, 110 does not include the gas supply 228, the valve 230, and / or the cable 232.

[0085] exist Figure 1A and / or Figure 1B In any of the example systems of FIG. 1 , the preheating power supply (e.g., the power conversion circuitry 30, the preheating power supply 108) can be configured to preheat the electrode wire 54 to a target temperature without using a temperature sensor to measure the temperature of the preheated welding wire. For example, the preheating power supply can use a temperature model (e.g., a predetermined relationship) to preheat the electrode wire 54 by identifying material properties of the electrode wire 54, determining or receiving a target preheating temperature, and controlling the preheating output using the temperature model to cause the electrode wire 54 to be preheated to the target temperature.

[0086] An example temperature model can relate the final preheat temperature of the wire electrode 54 to a heating energy input (e.g., in joules), relate a given wire electrode to a set of one or more material properties used to control preheating process parameters, relate the material properties of a given wire electrode recipe to a target temperature, and / or relate the target temperature and welding conditions (e.g., wire feed speed) to corresponding preheating parameters. In some examples, the temperature model is selected or adjusted based on the type of wire electrode 54. For example, the wire electrode can have different structures (e.g., solid wire, flux-cored wire, metal core, etc.), diameters (e.g., cross-sectional areas), and / or compositions (e.g., different solid metal alloys, cladding alloys, flux compositions, metal filler compositions, lubricant compositions, etc.), which can affect the resistivity and / or specific heat capacity of the resulting wire electrode 54.

[0087] In some examples, the temperature model can be adjusted using constants that control the different material properties of different electrode wires. These constants can be derived based on, for example, the target wire temperature, process parameters, and / or material properties. Additionally or alternatively, the constants and / or compensation factors can be determined empirically by measuring the wire temperature using contact methods and / or reliable non-contact methods.

[0088] During operation, the example control circuitry (eg, control circuitry 32, control circuitry 212) determines material properties of the electrode wire 54 to be preheated via wire preheating power (eg, using a temperature model).

[0089] Figure 3 An example user interface 300 is shown that can be used to input electrode wire characteristics to determine a target temperature. The example user interface 300 can implement Figure 1A The user interface 34 and / or Figure 2 The user interface 214. For example, the user interface 300 can be a touch screen, a display and an input device (eg, buttons, a mouse and cursor, etc.), and / or any other type of input and / or output device.

[0090] The example user interface 300 enables a user to select a welding wire type 302, a welding wire diameter 304, a target preheating temperature 306, a material thickness 308 of the workpiece 44, a material type 310 of the workpiece 44, and / or a gas type 312 (e.g., from a selection of multiple welding wire types). The example user interface 300 can further enable an operator to select or refine welding parameters and / or preheating parameters, such as welding voltage, wire feed speed, welding current, preheating voltage, preheating current, and / or any other desired welding parameters and / or preheating parameters. To this end, the user interface 300 includes example buttons 314, 316, 318, 320 for navigating the user interface 300, selecting features and / or parameters, and / or specifying values ​​for features and / or parameters. However, other input devices, such as a touch screen, knobs, buttons, and / or other input devices, can be used.

[0091] In some examples, the preheat target temperature may be input (e.g., via the user interface 300 and / or via the communication device as a target preheat temperature 306) and / or determined by the control circuitry 32, 212 based on an upper preheat temperature limit for a particular wire electrode. For example, different wire electrodes may have different temperatures at which they lose column strength and / or melt. Figure 4 is a table representing an example database 400 for storing target temperatures 402 and / or resistivities 404 associated with different welding wire types 406. Figure 4In the example of FIG406 , the wire types are assigned index numbers that can correspond to wire recipes, commercial electrode wires, and / or any other identifiers of electrode wire types. For each example wire type 406, the control circuitry 32 , 212 can access the corresponding target temperature 402 and / or resistivity 404. However, the database 400 can store other parameters, compensation factors, constants, and / or any other information about the stored electrode wires 406 to implement at least a portion of the temperature model.

[0092] The example control circuitry 32 , 212 may obtain or access an upper preheat temperature limit based on the determined or input electrode type and determine a target preheat temperature based on a percentage reduction or a constant deviation reduction from the upper preheat temperature limit.

[0093] In some examples, the control circuitry 32, 212 can select a default preheat target temperature based on the electrode type and / or material properties, and the operator can be allowed to adjust the preheat target temperature via the user interface 300. For example, lowering the preheat target temperature can result in an increase in the welding power output by the welding power conversion circuitry and an increase in the weld penetration. Conversely, increasing the preheat target temperature can result in a decrease in the welding power output and a decrease in the weld penetration.

[0094] The control circuitry 32, 212 determines one or more preheating process parameters for heating the electrode wire 54 to a target preheating temperature based on the material properties and the target temperature, a temperature model (e.g., a predetermined relationship) between the material properties and the preheating process parameter(s). Example preheating process parameters include preheating voltage, preheating current, wire resistance, preheating power, preheating enthalpy, wire feed speed, and / or preheating length.

[0095] The control circuit system 32, 212 can use the temperature model to relate the final preheating temperature to the initial temperature of the electrode wire 54, the material properties of the electrode wire 54 and / or the configuration of the preheating circuit, the diameter and / or cross-sectional area of ​​the electrode wire 54, and the wire feed speed. The initial temperature of the electrode wire 54 can be determined using, for example, the temperature sensor 78, which is configured to measure the ambient temperature and / or the temperature of the electrode wire 54 at the spool 64. Additionally or alternatively, the temperature can be input via the user interface 34 (e.g., the user inputs the ambient temperature via the user interface 300), the ambient temperature information can be obtained from a remote source (e.g., a temperature source on a network, a wireless ambient temperature sensor), and / or any other source via the communication circuit system.

[0096] Additionally or alternatively, when executing a welding sequence, a portion of the electrode wire 54 may be preheated from a previous weld, in which case the temperature input may be inaccurate. The example control circuitry 32, 212 may further model the temperature of the electrode wire 54 based on the time since the most recent weld to determine an initial temperature for the first portion of the subsequent weld and adjust the initial wire temperature (and corresponding preheat current parameters and / or preheat voltage parameters) during the initial preheat period of the subsequent weld.

[0097] The temperature model may include a predetermined relationship, such as a second-order polynomial, relating wire temperature to material properties and a plurality of preheating process parameters (e.g., wire feed speed, preheating current, preheating voltage, preheating power, preheating enthalpy, and / or preheating length). Alternatively, Equations 1 and 2 below illustrate another example relationship that may be used by the control circuitry 32, 212 to determine the preheating current for a given temperature.

[0098]

[0099] In Equations 1 and 2, I is the preheating current, temp is the target preheating temperature, b is the initial temperature of the electrode wire, m is a constant based on the material properties of the electrode wire 54 (e.g., resistivity, specific heat capacity) and / or based on the configuration of the preheating circuit (e.g., preheating length), A is the cross-sectional area of ​​the electrode wire 54, and v is the wire feeding speed of the electrode wire 54.

[0100] In some examples, the control circuitry 32 , 212 further determines additional preheating parameters based on the determined preheating current I. For example, in a voltage-controlled preheating control loop, the control circuitry 32 , 212 may determine the preheating voltage based on the preheating current, the actual or estimated resistance of the welding wire over the preheating length, and / or the preheating length.

[0101] During welding operations, the control circuitry 32, 212 controls the power conversion circuitry (e.g., the power conversion circuitry 30, 210) to output wire preheating power based on the preheating process parameter(s) that heat the wire electrode 54 to a target temperature. For example, the control circuitry 32, 212 may control the power conversion circuitry 30, 210 to output a determined preheating voltage and / or a determined preheating current that achieves a target preheating temperature for the wire electrode. The control circuitry 32, 212 monitors the preheating voltage, preheating current, preheating power, preheating enthalpy, wire resistance, and / or wire feed speed, and controls the preheating voltage and / or preheating current to preheat the wire electrode 54 to the target temperature.

[0102] If the wire feed speed or other welding variables change, the example control circuitry 32 may recalculate the preheat current and / or preheat voltage based on the temperature model.

[0103] Figure 5 is a flow chart representing example machine-readable instructions 500 that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 The example power supply of FIG. 500 is executed (eg, via the control circuit system 32 , 212 ) to output welding power and preheating power. The example instructions 500 are described below with reference to the control circuit system 32 .

[0104] At block 502, the control circuitry 32 determines the material properties of the electrode wire 54 to be preheated during the welding operation. For example, the control circuitry 32 may look up the material properties based on an identification of the electrode type and / or receive the material properties from the user interface 34. Example material properties include the initial temperature of the electrode wire 54, the cross-sectional area of ​​the electrode wire 54, the resistivity of the electrode wire 54, the density of the electrode wire 54, and / or the specific heat capacity of the electrode wire 54. Figure 6 An example implementation of block 502 is described below.

[0105] At block 504, the control circuitry 32 determines a target temperature for the preheated wire electrode 54. For example, the control circuitry 32 may determine the target temperature based on the material properties of the wire electrode 54 and / or the wire feed speed, and / or by looking up a target temperature for the electrode type in a database. In some examples, the target temperature may be input and / or adjusted via the user interface 34.

[0106] At block 506, the control circuit system 32 determines preheating process parameters (multiple) for heating the electrode wire 54 to the target temperature. For example, the control circuit system 32 may determine the preheating current, preheating voltage, preheating wire resistance, and / or any other process parameters. Figure 7 An example implementation of block 506 is described below.

[0107] At block 508, the control circuit system 32 determines whether the weld is valid. If the weld is valid (block 508), then at block 510, the control circuit system 32 controls the power conversion circuit system (e.g., the power conversion circuit system 30) to output wire preheating power based on the preheating process parameters that heat the electrode wire 54 to the target temperature. Figure 8 An example implementation of block 510 is described below.

[0108] If the weld is not valid (block 508), control returns to block 502 to determine whether the material properties of the wire electrode 54 have changed. In other examples, the control circuitry 32 may repeatedly perform block 508 until the weld is valid and / or until the wire electrode 54 changes.

[0109] In some examples, block 506 may also be repeatedly executed during welding to monitor and control the preheating process parameters. For example, the control circuitry 32 may apply the temperature model to recalculate the preheating process parameter(s) in response to changes or variations in the wire feed speed and / or initial wire temperature.

[0110] Figure 6 is a flow chart representing example machine-readable instructions 600 that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 The example power supply 12, 108 is executed to determine the material properties of the electrode wire to be preheated. The example instructions 600 may be executed by Figure 1A The control circuit system 32 and / or Figure 2 The control circuit system 212 executes to implement Figure 5 Block 502 of the flow chart determines the material properties of the wire electrode 54 to be preheated during the welding operation.

[0111] At block 602, the example control circuitry 32 determines whether a wire type input has been received via a user interface (e.g., wire type 302 of user interface 300). If a wire type input has been received via the user interface (block 602), then at block 604, the control circuitry 32 selects a wire type from a database (e.g., Figure 4 The material properties are obtained from the database 400), which include one or more of the cross-sectional area of ​​the electrode wire 54, the resistivity of the electrode wire 54, the density of the electrode wire 54, or the specific heat capacity of the electrode wire 54.

[0112] If no wire type input has been received via the user interface (block 602), then at block 606, the control circuit system 32 determines whether a wire type input has been received via a scanning device. For example, a spool or other electrode wire assembly may have a barcode, QR code, RFID tag, and / or other device that can provide information associated with the electrode wire 54. The example user interface 34 may include a scanner (e.g., an RFID reader or a barcode scanner) to obtain wire identification information and / or material properties from the wire assembly. If the user interface 34 receives wire identification information via the scanning device (block 606), then at block 608, the control circuit system 32 accesses a database based on the received wire type (e.g., identification information) to obtain material properties corresponding to the wire type.

[0113] If the welding wire type is not received via the scanning device (block 606), then at block 610, the control circuitry 32 determines whether material characteristics have been received via a user interface (e.g., user interface 34). For example, if the welding wire information is not stored in the database, the user interface 300 may enable the user to directly input the material characteristics of the welding wire.

[0114] If material properties have been received via the user interface (block 610 ), then at block 612 , the control circuitry 32 sets the material properties based on the material property information received via the user interface 34 .

[0115] After setting the material properties (block 612), if the material properties are not received via the user interface (block 610), then after obtaining the material properties from the database (block 608, block 604), the example instructions 600 end and return control to Figure 5 Frame 504.

[0116] Figure 7 is a flow chart representing example machine-readable instructions 700 that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 The example power supply 12, 108 is executed to determine the preheating process parameters for heating the electrode wire to the target temperature. The example instructions 700 can be executed by Figure 1A The control circuit system 32 and / or Figure 2 The control circuit system 212 executes to implement Figure 5 Frame 506.

[0117] At block 702, the control circuitry 32 determines a preheating current to achieve a target preheating temperature for the wire electrode 54 based on the initial temperature of the wire electrode 54 and the material properties of the wire electrode 54. For example, the control circuitry 32 may use the example equation 2 above based on the Figure 5 In block 502 (e.g., via Figure 6 The preheating current is determined based on the material properties determined by instruction 600 ), the measured initial temperature of the electrode wire 54 , and the determined target preheating temperature (eg, determined in block 504 ).

[0118] The initial temperature can be determined using, for example, temperature measurements of the ambient temperature (e.g., the environment surrounding the wire feeder or wire assembly), temperature measurements of the wire assembly (e.g., the spool 64 or other source of electrode wire 54) via the temperature sensor 78, temperature measurements of one or more elements of the welding torch 14 via the temperature sensor 78, temperature measurements of the torch coolant via the temperature sensor 78, a temperature input via the user interface 34 (e.g., the ambient temperature input by the user via the user interface 300), ambient temperature information obtained from a remote source via the communication circuit system (e.g., a network temperature source, a wireless ambient temperature sensor), and / or any other source.

[0119] Additionally or alternatively, when executing a weld sequence, a portion of the electrode wire 54 may be preheated from a previous weld, in which case the temperature input may be inaccurate. The example control circuitry 32 may further model the temperature of the electrode wire 54 based on the time since the most recent weld to determine an initial temperature for the first portion of a subsequent weld and adjust the initial wire temperature (and corresponding preheat current parameters and / or preheat voltage parameters) during the initial preheat period of the subsequent weld.

[0120] At block 704, the control circuitry 32 determines a voltage corresponding to the determined current. For example, in a voltage-controlled preheating control loop, the control circuitry 32 may control the power conversion circuitry 30 to output preheating power based on a target voltage. Additionally or alternatively, the control circuitry 32 may monitor and / or control the resistance of the wire electrode 54 to a target resistance (which may correspond to a target temperature) by monitoring the voltage across and the current through the preheating section 56.

[0121] The example instructions 700 may then end and return control to Figure 5 Frame 508.

[0122] Figure 8 is a flow chart representing example machine-readable instructions 800 that may be executed by Figure 1A 、 Figure 1B and / or Figure 2 The example power supply 12, 108 of the embodiment of the present invention is executed to control the power conversion circuit system 30, 210 to output the welding wire preheating power. The example instruction 800 can be executed by Figure 1A The control circuit system 32 and / or Figure 2 The control circuit system 212 executes to implement Figure 5 Frame 510.

[0123] At block 802, the power conversion circuitry 30 receives a power input (eg, Figure 1AAt block 804, the control circuitry 32 determines (e.g., based on the welding process parameters) whether the welding output is enabled. If the welding output is enabled (block 804), then at block 806, the control circuitry 32 controls the power conversion circuitry 30 to convert the input power 22 into the welding power output based on the determined welding power output.

[0124] At block 808, the power conversion circuitry 30 outputs the welding output to the welding torch 14. For example, the welding output is conducted to the contact tip 18 and the work cable 42 to generate the arc 26.

[0125] After outputting welding-type power (block 808), or if welding output is disabled (block 804), at block 810, the control circuitry 32 determines (e.g., based on preheating process parameters) whether to enable preheating. For example, the control circuitry 32 can selectively enable the power conversion circuitry 30 to provide preheating output (e.g., to the contact tips 18, 20) and selectively disable the power conversion circuitry 30 to stop preheating output. The control circuitry 32 can enable and / or disable preheating based on, for example, user input via the user interface 34 and / or input from the power supply, remote control, and / or welding torch 14.

[0126] If the preheat output is enabled (block 810), the power conversion circuitry 30 converts at least a portion of the input power to the preheat output based on the determined preheat output at block 812. For example, the control circuitry 32 may control the power conversion circuitry 30, 210 to convert the main power 22 to the preheat output.

[0127] At block 814, the power conversion circuitry 30 outputs welding-type power to the welding torch 14. For example, the preheating output is conducted to the contact tips 18 and 20 via the conductors 70, 72.

[0128] After preheat power is output (block 814), or if preheat is disabled (block 810), the example instructions 800 end and control returns to Figure 5 The example instructions 800 may be repeated via blocks 508 and 510.

[0129] The present apparatus and / or method can be implemented in hardware, software, or a combination of hardware and software. The present method and / or system can be implemented in a centralized manner in at least one computing system, processor, and / or other logic circuit, or in a distributed manner with different elements spread across several interconnected computing systems, processors, and / or other logic circuits. Any type of computing system or other device suitable for executing the methods described herein is suitable. A typical combination of hardware and software can be a processing system with a program or other code integrated into a welding power supply that controls the welding power supply when loaded and executed so that it implements the methods described herein. Another typical embodiment can include a dedicated integrated circuit or chip, such as a field programmable gate array (FPGA), a programmable logic device (PLD), or a complex programmable logic device (CPLD) and / or a system on chip (SoC). Some embodiments can include a non-transitory machine-readable (e.g., computer-readable) medium (e.g., flash memory, an optical disk, a magnetic storage disk, etc.) having one or more lines of code executable by a machine stored thereon, thereby causing the machine to perform the process described herein. As used herein, the term "non-transitory machine-readable medium" is defined to include all types of machine-readable storage media and to exclude propagating signals.

[0130] Example control circuit implementations can be a microcontroller, field programmable logic circuit, and / or any other control or logic circuit capable of executing instructions of the welding control software. The control circuit can also be implemented as analog circuitry and / or a combination of digital and analog circuitry.

[0131] Although the present method and / or system 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 present method and / or system. Additionally, many modifications may be made to adapt particular 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, divided, rearranged and / or otherwise modified. Therefore, the present method and / or system is not limited to the specific embodiments disclosed. Alternatively, the present method and / or system will include all embodiments that fall within the scope of the appended claims, both literally and according to the doctrine of equivalents.

Claims

1. A welding power supply comprising: a power conversion circuit system configured to convert input power into wire preheating power and output the wire preheating power to a preheating system; as well as a control circuit system configured to determine at least one of a plurality of preheating process parameters based on a temperature model and a target temperature of the wire electrode, and thereby control the power conversion circuit system based on the at least one of the plurality of preheating process parameters to preheat the wire electrode to the target temperature via the preheating system; wherein the temperature model comprises a second-order polynomial relating the target temperature to the plurality of preheating process parameters, wherein the plurality of preheating process parameters comprise two or more parameters of wire feed speed, preheating current, preheating voltage, preheating power, preheating resistance, preheating enthalpy, or preheating length; Wherein, the control circuit system is further configured to: If a portion of the wire electrode has been preheated, adjusting the initial temperature of the wire electrode and corresponding preheating current parameters and / or preheating voltage parameters during an initial preheating period of a subsequent weld, and After adjusting the initial temperature of the wire electrode and the corresponding preheating current parameters and / or preheating voltage parameters, the power conversion circuit system is controlled to preheat the wire electrode to the target temperature via the preheating system.

2. The welding power supply according to claim 1, wherein The control circuitry is configured to control the power conversion circuitry to preheat the wire electrode to the target temperature without using a temperature sensor to measure the temperature of the preheated wire electrode.

3. The welding power supply according to claim 1, wherein: The control circuit system is configured to control the power conversion circuit system by applying the temperature model based on one or more of the following: the initial temperature of the electrode wire, the cross-sectional area of ​​the electrode wire, the resistivity of the electrode wire, the density of the electrode wire, or the specific heat capacity of the electrode wire.

4. The welding power supply according to claim 3, wherein: The control circuitry is configured to control the power conversion circuitry by applying the temperature model based on a wire feed speed of the wire electrode.

5. The welding power supply of claim 3 , further comprising a user interface configured to receive input specifying one or more of an initial temperature of the wire electrode, a cross-sectional area of ​​the wire electrode, a resistivity of the wire electrode, a density of the wire electrode, or a specific heat capacity of the wire electrode.

6. The welding power supply according to claim 1, wherein: The control circuitry is configured to determine one or more of the plurality of preheating parameters by accessing a storage device storing the plurality of preheating parameters corresponding to the temperature model.

7. The welding power supply according to claim 1, wherein: The temperature model is based on the following equation: Wherein, b is the initial temperature of the electrode wire, m is a constant based on one or more material properties of the electrode wire, I is the preheating current of the wire preheating power, A is the cross-sectional area of ​​the electrode wire, v is the wire feeding speed of the electrode wire, and temp is the target temperature.

8. A preheating power supply comprising: a power conversion circuit system configured to convert input power into wire preheating power and output the wire preheating power to the preheating circuit; as well as control circuitry, the control circuitry being configured to: determining a material property of an electrode wire to be preheated via the wire preheating power, the material property comprising one or more of: an initial temperature of the electrode wire, a resistivity of the electrode wire, a density of the electrode wire, or a specific heat capacity of the electrode wire; determining at least one of the plurality of preheating process parameters for preheating the wire electrode to the target temperature based on the material property, the target temperature of the wire electrode, and a first predetermined relationship between the target temperature, the material property, and a plurality of preheating process parameters, wherein the first predetermined relationship comprises a second-order polynomial relating the target temperature to the plurality of preheating process parameters, wherein the plurality of preheating process parameters comprise two or more parameters of wire feed speed, preheating current, preheating voltage, preheating power, preheating resistance, preheating enthalpy, or preheating length; and controlling the power conversion circuit system to output the wire preheating power based on the at least one of the plurality of preheating process parameters for preheating the electrode wire to the target temperature; Wherein, the control circuit system is further configured to: If a portion of the wire electrode has been preheated, adjusting the initial temperature of the wire electrode and corresponding preheating current parameters and / or preheating voltage parameters during an initial preheating period of a subsequent weld, and After adjusting the initial temperature of the electrode wire and the corresponding preheating current parameters and / or preheating voltage parameters, the power conversion circuit system is controlled to output the welding wire preheating power to preheat the electrode wire to the target temperature via the preheating circuit.

9. The preheating power supply of claim 8, further comprising one or more input devices, the control circuitry being configured to determine at least one of the material properties based on input received via the one or more input devices.

10. The preheating power supply according to claim 9, wherein The input includes an identification of the welding wire type.

11. The preheating power supply according to claim 10, wherein: The control circuitry is configured to determine the material characteristic based on an identification of the welding wire type.

12. The preheating power supply according to claim 10, wherein: The control circuitry is configured to determine the wire diameter based on the input, or to automatically determine the wire diameter.

13. The preheating power supply of claim 8, further comprising one or more input devices, the control circuitry being configured to determine the target temperature based on one or more inputs received via the one or more input devices.

14. The preheating power supply according to claim 8, wherein The control circuit system is configured to determine the preheating current I of the wire preheating power based on the following equation as the first predetermined relationship: Wherein, b is the initial temperature of the wire electrode, m is a constant based on at least one of the material properties of the wire electrode or the configuration of the preheating circuit, A is the cross-sectional area of ​​the wire electrode, v is the wire feeding speed of the wire electrode, and temp is the target temperature.

15. The preheating power supply according to claim 8, wherein The preheating circuit includes a first contact tip of a welding torch and a second contact tip of the welding torch.

16. The preheating power supply according to claim 8, wherein The control circuitry is configured to select the first predetermined relationship from a plurality of predetermined relationships.

17. The preheating power supply according to claim 8, wherein The control circuitry is configured to control the power conversion circuitry to preheat the wire electrode to the target temperature without using a temperature sensor to measure the temperature of the preheated wire electrode.

18. The preheating power supply according to claim 8, wherein The control circuitry is configured to determine the target temperature to which the wire electrode is to be preheated.

19. A welding power supply comprising: a power conversion circuit system configured to convert input power into wire preheating power and output the wire preheating power to a preheating system; as well as a control circuit system configured to determine a target temperature of the wire electrode based on material properties of the wire electrode, and calculate at least one of a plurality of preheating process parameters for preheating the wire electrode to the target temperature using a temperature model, thereby controlling the power conversion circuit system based on the at least one of the plurality of preheating process parameters to preheat the wire electrode to the target temperature via the preheating system; wherein the temperature model comprises a second-order polynomial relating the target temperature to the plurality of preheating process parameters, wherein the plurality of preheating process parameters comprise two or more parameters of wire feed speed, preheating current, preheating voltage, preheating power, preheating resistance, preheating enthalpy, or preheating length; and Wherein, the control circuit system is further configured to: If a portion of the wire electrode has been preheated, adjusting the initial temperature of the wire electrode and corresponding preheating current parameters and / or preheating voltage parameters during an initial preheating period of a subsequent weld, and After adjusting the initial temperature of the wire electrode and the corresponding preheating current parameters and / or preheating voltage parameters, the power conversion circuit system is controlled to preheat the wire electrode to the target temperature via the preheating system.

20. A preheating power supply comprising: a power conversion circuit system configured to convert input power into wire preheating power and output the wire preheating power to the preheating circuit; as well as control circuitry, the control circuitry being configured to: determining a material property of an electrode wire to be preheated via the wire preheating power, the material property comprising one or more of: an initial temperature of the electrode wire, a resistivity of the electrode wire, a density of the electrode wire, or a specific heat capacity of the electrode wire; determining a target temperature of the wire electrode based on the material properties; calculating at least one of the plurality of preheating process parameters for preheating the electrode wire to the target temperature using a first predetermined relationship between the target temperature, the material property, and a plurality of preheating process parameters, wherein the first predetermined relationship comprises a second-order polynomial relating the target temperature to the plurality of preheating process parameters, wherein the plurality of preheating process parameters comprise two or more parameters of wire feed speed, preheating current, preheating voltage, preheating power, preheating resistance, preheating enthalpy, or preheating length; and controlling the power conversion circuit system to output the wire preheating power based on the at least one of the plurality of preheating process parameters for preheating the electrode wire to the target temperature; Wherein, the control circuit system is further configured to: If a portion of the wire electrode has been preheated, adjusting the initial temperature of the wire electrode and corresponding preheating current parameters and / or preheating voltage parameters during an initial preheating period of a subsequent weld, and After adjusting the initial temperature of the electrode wire and the corresponding preheating current parameters and / or preheating voltage parameters, the power conversion circuit system is controlled to output the welding wire preheating power to preheat the electrode wire to the target temperature via the preheating circuit.

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