Welding diagnostic device for identifying metal transfer modes during a welding process and a method of identifying metal transfer modes of a welding process

A method of identifying a metal transfer mode of a welding process presently being performed, comprising:

• analyzing a welding voltage obtained, employing a voltage sensor, from a welding machine during a welding process;
• determining a threshold during said welding process solely from an average of said welding voltage;
• determining, employing a processor, a number of voltage drops of said welding voltage below said threshold in a designated amount of time that corresponds to said welding process;
• identifying a metal transfer mode of said welding process performed by said welding machine based on said number of voltage drops;
• and
• providing at least one sensory indication of said metal transfer mode employing a viewable identifier.

A transfer mode identifier for use with a welding machine, comprising:

• a welding data interface configured to receive a welding voltage from power terminals of said welding machine during a welding process;
• a voltage sensor configured to read said welding voltage from said welding data interface;
• a data acquisition system configured to, during said welding process, determine a threshold solely from an average of said welding voltage, determine a number of drops of said voltage below said threshold in a designated amount of time, and determine metal transfer modes of said welding process based on said number of drops, wherein said data acquisition system is configured to determine said threshold over a particular amount of time that corresponds to said welding process;
• a viewable identifier configured to visually indicate said metal transfer modes in real time during said welding process;
• and
• a voltage sensor configured to read said welding voltage from said welding data interface and provide said welding voltage to said data acquisition system.