Systems and methods for diagnosing secondary weld errors
A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.
1. A controller for a welding system, configured to:
determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter acquired via shorting of a welding torch tip to the weld secondary component via a test contact;
compare the determined value to a reference value range; and
alert a user to a presence and location of a weld secondary error when the determined value is outside the reference value range.
2. The controller of claim 1 , further configured to receive an input from the user regarding a negative weld lead length, and to determine the reference value range based on the negative weld lead length.
3. The controller of claim 1 , further configured to receive an input from the user regarding a negative weld lead size, and to determine the reference value range based on the negative weld lead size.
4. The controller of claim 1 , further configured to receive an input from the user regarding a positive weld lead length, and to determine the reference value range based on the positive weld lead length.
5. The controller of claim 1 , further configured to receive an input from the user regarding a positive weld lead size, and to determine the reference value range based on the positive weld lead size.
6. The controller of claim 1 , further configured to receive an input from the user regarding a welding torch manufacturer, and to determine the reference value range based on the welding torch manufacturer.
7. The controller of claim 1 , further configured to receive an input from the user regarding a welding torch model number, and to determine the reference value range based on the welding torch model number.
8. The controller of claim 1 , further configured to receive an input from the user regarding a welding torch length, and to determine the reference value range based on the welding torch length.
9. The controller of claim 1 , wherein the reference range value is determined based on a measured value of an initial drop in the weld secondary parameter across the weld secondary component based on the sensed parameter at a prior time.
10. The controller of claim 1 , wherein the weld secondary parameter is at least one of a voltage, a current, a power, a resistance, a conductance, and an inductance.
11. The controller of claim 1 , wherein the weld secondary component is weld cabling.
12. The controller of claim 1 , wherein the weld secondary component is a welding torch.
13. The controller of claim 1 , wherein the weld secondary component is a rotary ground.
14. The controller of claim 1 , wherein the weld secondary component is weld fixturing.
15. The controller of claim 1 , wherein the weld secondary component is a welding workpiece.
16. The controller of claim 1 , further configured to store the determined value of the weld secondary parameter to a memory.
17. A controller for a welding system, configured to:
determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter;
receive an input via a user interface, wherein the input relates to a negative weld lead length, a negative weld lead size, a positive weld lead length, a positive weld lead size, a welding torch manufacturer, a welding torch model number, or a welding torch length;
determine a reference value range based on the received input;
compare the determined value to the determined reference value range; and
alert a user, via the user interface, to a presence and location of a weld secondary error when the determined value is outside the determined reference value range.
18. The controller of claim 17 , wherein the received input relates to the negative weld lead length.
19. The controller of claim 17 , wherein the received input relates to the negative weld lead size.
20. The controller of claim 17 , wherein the received input relates to the positive weld lead length.
21. The controller of claim 17 , wherein the received input relates to the positive weld lead size.
22. The controller of claim 17 , wherein the received input relates to the welding torch manufacturer.
23. The controller of claim 17 , wherein the received input relates to the welding torch model number.
24. The controller of claim 17 , wherein the received input relates to the welding torch length.
25. The controller of claim 17 , wherein the weld secondary parameter is at least one of a voltage, a current, a power, a resistance, a conductance, and an inductance.
26. The controller of claim 17 , wherein the weld secondary component is weld cabling, a welding torch, a rotary ground, weld fixturing, or a welding workpiece.
27. The controller of claim 17 , further configured to store the determined value of the weld secondary parameter to a memory.
28. The controller of claim 17 , wherein the sensed parameter is acquired via shorting of a welding torch tip to the weld secondary component via a test contact.