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US 8,963,045 B2Granted
Non-linear adaptive control system and method for welding
AssigneeLincoln Global, Inc.
InventorsSteven R. Peters, Bruce E. Fulmer
Life of this patent
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Abstract
Nonlinear adaptive welders and power source controls are provided along with welding methods method for regulating a welding process, in which one or more welding waveform parameters are adapted in nonlinear fashion based on measured welding process feedback information.
Claims19
A welding system, comprising:
- a power source with an output configured to provide a welding signal as a series of waveforms during a welding process;
- a feedback system operatively coupled with said power source and configured to sense at least one feedback parameter associated with said welding process,
- said at least one feedback parameter having a non-linear relationship with at least one waveform parameter of said welding signal, said non-linear relationship providing a larger adaptive range of control defined at least in part by a minimum feedback parameter value associated with a minimum waveform parameter value and a maximum feedback parameter value associated with a maximum waveform parameter value;
- and
- a controller operatively coupled with said feedback system and with said power source, said controller configured to:
- compare said feedback parameter to a setpoint value to derive an error value,
- determine a parameter scaling factor for said at least one controlled waveform parameter based on a current workpoint value and said error value, said parameter scaling factor varying as a function of said error value over said larger adaptive range of control, and
- modify values of said at least one waveform parameter in response to values of said feedback parameter in accordance with said non-linear relationship, said error value, and said parameter scaling factor such that said larger adaptive range of control has a greater magnitude than a narrower range of adaptive control which can be achieved by a linear relationship between said at least one feedback parameter and said at least one waveform parameter.
5 more elements
A method for regulating a welding process, said method comprising:
- sensing at least one feedback parameter associated with said welding process,
- said at least one feedback parameter having a non-linear relationship with at least one waveform parameter of a welding signal, said non-linear relationship providing a larger adaptive range of control defined at least in part by a minimum feedback parameter value associated with a minimum waveform parameter value and a maximum feedback parameter value associated with a maximum waveform parameter value;
- and
- selectively modifying at least one controlled waveform parameter of said welding signal in response to said at least one feedback parameter in accordance with said non-linear relationship, such that said larger adaptive range of control has a greater magnitude than a narrower adaptive range of control which can be achieved by a linear relationship between said at least one feedback parameter and said at least one waveform parameter,
- wherein selectively modifying at least one controlled waveform parameter comprises:
- comparing said feedback parameter to a setpoint value to derive an error value;
- determining a parameter scaling factor for said at least one controlled waveform parameter based on a current workpoint value and said error value, said parameter scaling factor varying as a function of said error value over said larger adaptive range of control;
- and
- selectively modifying said at least one controlled waveform parameter according to said error value and said parameter scaling factor.
6 more elements
A control system for regulating the output welding signal of a welding power source in a welding process, said control system comprising:
- means for sensing at least one feedback parameter associated with said welding process,
- said at least one feedback parameter having a non-linear relationship with at least one waveform parameter of said welding signal, said non-linear relationship providing a larger adaptive range of control defined at least in part by a minimum feedback parameter value associated with a minimum waveform parameter value and a maximum feedback parameter value associated with a maximum waveform parameter value;
- and
- means for selectively adapting at least one controlled waveform parameter of said welding signal in response to said at least one feedback parameter in accordance with said non-linear relationship, such that said larger adaptive range of control has a greater magnitude than a narrower range of adaptive control which can be achieved by a linear relationship between said at least one feedback parameter and said at least one waveform parameter,
- wherein said means for selectively modifying at least one controlled waveform parameter includes:
- means for comparing said feedback parameter to a setpoint value to derive an error value;
- means for determining a parameter scaling factor for said at least one controlled waveform parameter based on a current workpoint value and said error value, said parameter scaling factor varying as a function of said error value over said larger adaptive range of control;
- and
- means for selectively modifying said at least one controlled waveform parameter according to said error value and according to said parameter scaling factor.
6 more elements
Dependencies are inferred from the claim text.