Apparatus and method for computerized interactive control, measurement and documentation of arc welding

An apparatus to facilitate the consistent performance of precision welding, comprising:

• a power source;
• a power source controller;
• means for producing an electric arc;
• means for heating a workpiece;
• means for sensing temperature of the workpiece;
• said power source controller including a monitor and interactive control circuitry to monitor power demand and supply of the means for producing an electric arc and power demand and supply of the means for heating a workpiece;
• said power source controller further including means for producing an alarm when demand from the means for producing an electric arc occurs above or below a first predetermined range of deviation from a predetermined optimum interpass temperature;
• said power source controller further including means for temporarily interrupting power output from the power source to the means for producing an electric arc when demand from the means for producing an electric arc occurs above or below a second predetermined range of deviation from the predetermined optimum interpass temperature;
• said power source controller further including means for automatically adjusting output of the power source in response to deviations in the temperature of the workpiece as sensed by the means for sensing temperature of the workpiece;
• means for electronically acquiring and storing welding operational parameters and workpiece operational parameters monitored during welding operations for subsequent retrieval and display;
• means for providing to an operator of the apparatus contemporaneous feedback of welding operational parameters and workpiece operational parameter and alarm status during welding operation;
• and
• means for data input to the power source controller;
• said power source controller controlling the power source to interactively provide power output to the means for producing an electric arc and to the means for heating a workpiece in response to input from the means for heating the workpiece, input from the means for sensing the temperature of the workpiece, input from the means for producing an electric arc, input from the means for data input, means for automatically adjusting output of the power source in response to deviations in the temperature of the workpiece,
• and predetermined welding operational parameters.

An apparatus for heat treatment of a workpiece powered from a power main having other electrical equipment drawing power from said power main, comprising:

• a power source;
• a power source controller;
• means for heating a workpiece;
• means for sensing temperature of the workpiece;
• said power source controller modulating power output to the means for heating a workpiece in response to input from the means for heating the workpiece, input from the means for sensing the temperature of the workpiece and predetermined workpiece operational parameters;
• and
• said power source controller capable of modulating power output to the means for heating a workpiece without interfering with supply of power to additional electrical equipment powered by said power main.

A method to facilitate consistent precision are welding operations, comprising the steps of:

• assigning a weld procedure for a welding operation;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• interactively welding in response to contemporaneous feedback of welding operational parameters, temporary interruption of the welding operation, workpiece operational parameters and alarms;
• and
• acquiring and storing a log of welding operational parameters.

A method of evaluating performance of a welding operator, comprising the steps of:

• assigning a weld procedure for a welding operation to evaluate performance of the welding operator;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• causing the welding operator to interactively weld in response to contemporaneous feedback of welding operational parameters, temporary interruption of the welding operation, workpiece operational parameters, and alarms;
• acquiring and storing a log of welding operational parameters;
• and
• comparing the log of welding operational parameters recorded to the assigned weld procedure to evaluate the performance of the welding operator.

A method of training welding operators, comprising the steps of:

• assigning a weld procedure for a welding operation;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• causing one or more welding operators to interactively weld in response to contemporaneous feedback of welding operational parameters, temporary interruption of the welding operation, workpiece operational parameters, and alarms;
• acquiring and storing a log of welding operational parameters;
• and
• displaying the log of welding operational parameters acquired and stored and the assigned weld procedure to train the welding operators.

A method of ensuring compliance with mandated or recommended weld practices and procedures, comprising the steps of:

• assigning a mandated or recommended weld procedure for a welding operation;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• interactively welding in response to contemporaneous feedback of welding operational parameters, temporary interruption of the welding operation, workpiece operational parameters, and alarms;
• acquiring and storing a log of welding operational parameters;
• and
• comparing the log of welding operational parameters recorded to the required weld procedure to verify compliance with the procedure.

A method of determining the cause of a weld joint to fail NDT inspection, comprising the steps of:

• assigning a required weld procedure for a welding operation;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• interactively welding in response to contemporaneous feedback of welding operational parameters, temporary interruption of the welding operation, workpiece operational parameters, and alarms;
• acquiring and storing a log of welding operational parameters and workpiece operational parameters;
• and
• examining the log of welding operational parameters and workpiece operational parameters acquired and stored to determine cause of welded joint to fail NDT inspection.

A method of determining whether immediate post weld treatment of a weld is feasible without the need for cooling and/or examining the workpiece, comprising the steps of:

• assigning a weld procedure for a welding operation;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• interactively welding in response to contemporaneous feedback of welding operational parameters, temporary interruption of the welding operation, workpiece operational parameters, and alarms;
• acquiring and storing a log of welding operational parameters and workpiece operational parameters;
• and
• examining the log of welding operational parameters and workpiece operational parameters acquired and stored to determine cause of welded joint to fail NDT inspection.

A method for eliminating the need for post weld heat treatment for a welding operation, comprising the steps of:

• assigning a temperbead weld procedure for a welding operation;
• entering optimum welding operational parameters and workpiece operational parameters for said procedure into an apparatus for facilitating precision welding;
• interactively welding in response to contemporaneous feedback of welding operational parameters, temporary, interruption of the welding operation, workpiece operational parameters, and alarms;
• acquiring and storing a log of welding operational parameters and workpiece operational parameters;
• and
• examining the log of welding operational parameters and workpiece operational parameters acquired and stored to confirm effectiveness of said procedure.