Weld Heat Input Tracking Using Segmented Power Measurement
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Solution Overview
Problem
Conventional welding equipment makes it difficult for users to track changes in power input during a weld and measure overall heat input, especially when the user is also responsible for performing the weld, due to unfriendly display formats and the need to monitor multiple parameters simultaneously.
Innovation Solution
A welding-type power supply system that monitors and calculates average instantaneous power values for discrete time periods, displaying both total average instantaneous power and duration of the weld, allowing users to track heat input effectively and comply with welding codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding equipment displays instantaneous power only, then the device complexity is low, but the ease of operation deteriorates because users cannot track changes in power input throughout the weld
Solution Approach 1:
The patent segments the continuous welding process into discrete time periods and calculates average instantaneous power for each segment. This allows users to track power changes throughout the weld by reviewing segmented data after completion, rather than requiring complex real-time display systems during the welding process.
2Measurement precision
If conventional welding equipment displays accumulated energy, then the measurement precision of overall heat input is improved, but the ease of operation deteriorates because the display is not friendly to track changes of heat input based on location within a weld
Solution Approach 1:
The patent divides the weld into discrete time periods and calculates average instantaneous power for each segment. Users can then track changes in heat input based on location within the weld by reviewing the segmented data, making it easier to understand heat input distribution throughout the welding process.
Solution Approach 2:
The patent adds a temporal dimension to heat input tracking by organizing data into discrete time periods. This allows users to track heat input changes over time and correlate them with specific locations in the weld, transforming a single accumulated value into a time-resolved profile.
3Measurement precision
If the user must monitor multiple parameters simultaneously, then the measurement precision of welding parameters is maintained, but the ease of operation deteriorates especially when the user is also responsible for performing the weld
Solution Approach 1:
The patent performs preliminary calculations of average instantaneous power for discrete time periods during the welding process. This preliminary action captures all necessary measurement data automatically, allowing users to review comprehensive welding parameter information after the weld is complete without having to monitor multiple parameters simultaneously during the process.
4Loss of information
If conventional welding equipment provides simple display, then the device complexity is low, but the loss of information increases because users cannot determine overall heat input to the weld
Solution Approach 1:
The patent segments welding data into discrete time periods with calculated average instantaneous power values. This segmentation preserves detailed information about power input throughout the weld while maintaining relatively simple processing and display requirements, preventing information loss without significantly increasing device complexity.
Data Source
AI summary
Methods and apparatus to determine heat input to a weld are disclosed. An example welding-type power supply includes a power converter to convert input power to output welding-type power, and a controller configured to: during a welding-type operation, calculate average instantaneous power values of the welding-type operation for discrete, non-overlapping time periods by multiplying voltage measurements and corresponding current measurements; identify an end of the welding-type operation; determine a duration of the welding-type operation; calculate a total average instantaneous power of the welding-type operation based on the average instantaneous power values for the time periods and the duration of the welding-type operation; and determine whether an acceptable range of the welding-type operation is exceeded based on the total average instantaneous power and the duration of the welding-type operation.