Welding machine with automatic parameter setting

Abstract

A method and apparatus for welding that includes power source and a wire feeder is disclosed. One or more sensors sense one or more welding conditions before the weld is initiated. A set up circuit is coupled to sensor, the power source, and the wire feeder. The set up circuit automatically sets up the welding machine in response to what the sensor senses. The sensor may be a wire sensor, including a diameter sensor and a material sensor, a gas sensor (if a source of gas is included) such as a cyclic voltametry gas microsensor, a workpiece thickness sensor such as a strain gauge or displacement sensor. Alternatively the sensor includes a bar code reader that reads a code on, for example, the spool of wire, an analog proximity detector, a plurality of proximity detectors, and a displacement sensor.

Description

FIELD OF THE INVENTION [0001] The present invention relates generally to welding machines. More specifically, it relates to a welding machine that senses one or more conditions of a welding job and automatically sets operating parameters. BACKGROUND OF THE INVENTION [0002] Metal-inert-gas (MIG) welding is one well known type of welding process. There are a number of different types of power supplies used for MIG welding. Examples of MIG power supplies include phase controlled, pulse width modulated and inverter power supplies. MIG welding is performed using a variety of wire diameters, wire material, and gasses. The wire and gas used depends on the plate or workpiece thickness and material. Wire diameter, wire material, gas and plate thickness are referred to herein as welding conditions. [0003] Most MIG welding machines use at least three parameters to control the welding process. These parameters are: wire feed speed and / or current, voltage, and inductance. Some MIG welding machin...

AI Technical Summary

Benefits of technology

The invention is a welding machine that includes a power source and a wire feeder. The machine has a sensor that detects various welding conditions, and a set up circuit that automatically adjusts the machine based on the sensor. The sensor can be a wire sensor, a gas sensor, a workpiece thickness sensor, or a diameter sensor, among others. The set up circuit can adjust the machine based on the sensor inputs, making the welding process more efficient and effective.

Problems solved by technology

If the operator provides erroneous data, or doesn't properly calculate the setup parameters, the result may be poor quality welds or inefficient use of the welding machine or consumables (gas and wire).

It is not unusual for the operators to improperly select the setup parameters and have such poor quality welds that a service call is required.

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