Automatic weld arc monitoring system
An example welding system includes a power supply configured to output welding power; a weld parameter feedback sensor configured to produce a weld feedback parameter corresponding to an actual weld condition during welding; and a welding program comprising: a first weld having first weld parameters; a second weld having second weld parameters, wherein the second weld follows the first weld; a controller configured to, in response to selection of the weld program for performing a welding job on a part: control the power supply to provide the welding power to a first weld operation based the first weld parameters; monitor first feedback from the power supply; control the power supply to provide the welding power to a second weld operation based the second weld parameters; monitor second feedback from the power supply; and determine whether at least one of the welding job or the part is acceptable.
1. A welding system comprising:
a power supply configured to output welding power;
a weld parameter feedback sensor configured to monitor at least one of a current feedback signal, a wire feed speed feedback signal, or a voltage feedback signal from the weld, the weld parameter feedback sensor configured to produce a weld feedback parameter corresponding to an actual weld condition during welding;
a machine readable storage device configured to store a welding program, the welding program comprising:
a first weld having first weld parameters; and
a second weld having second weld parameters, wherein the second weld follows the first weld in an order of welds in the welding program; and
a controller configured to, in response to selection of the weld program for performing a welding job on a part:
control the power supply to provide the welding power to a first weld operation based on first command values;
during the first weld operation, monitor first feedback from the power supply, the first feedback corresponding to at least one of the first weld parameters;
after the first weld operation is completed, control the power supply to provide the welding power to a second weld operation based on second command values;
during the second weld operation, monitor second feedback from the power supply, the second feedback corresponding to at least one of the second weld parameters; and
determine whether at least one of the welding job or the part is acceptable, based on comparing the first feedback to first parameter limits, comparing the first command values to the first parameter limits, comparing the second feedback to second parameter limits, and comparing the second command values to the second parameter limits.
2. The welding system as defined in claim 1 , wherein the controller is configured to calculate at least one of the first parameter limits based on the first weld parameters or the second parameter limits based on the second weld parameters.
3. The welding system as defined in claim 1 , wherein the controller is configured to calculate one or both of the first parameter limits or the second parameter limits based on an operator performing the welding job.
4. The welding system as defined in claim 1 , wherein at least one of the weld program or the first weld specifies the first parameter limits, and at least one of the weld program or the second weld specifies the second parameter limits.
5. The welding system as defined in claim 1 , wherein the controller is configured to output an alarm signal in response to the first feedback exceeding the first parameter limits or in response to the second feedback exceeding the second parameter limits.
6. The welding system as defined in claim 1 , wherein the controller is configured to prevent changes to the first parameters or the second parameters by an operator performing the welding job.
7. The welding system as defined in claim 1 , wherein the controller is configured to prevent or allow the changes to the first parameters or the second parameters by the operator performing the welding job based on an identifier of the operator.
8. The welding system as defined in claim 1 , wherein the controller is configured to determine a change to the first command values based on comparing the first command values to the first feedback.