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 system comprising:
a weld secondary component; and
a processor configured to execute instructions stored in a tangible machine-readable memory medium, the instructions comprising instructions for:
determining a value of a weld secondary parameter across the weld secondary component based on a sensed parameter acquired via shorting of a welding torch tip to the weld secondary component;
comparing the determined value to a reference value range; and
alerting a user to a presence and location of a weld secondary error when the determined value is outside the reference value range.
2. The system of claim 1 , wherein the instructions include instructions for receiving an input from the user regarding a negative weld lead length, and instructions for determining the reference value range based on the negative weld lead length.
3. The system of claim 1 , wherein the instructions include instructions for receiving an input from the user regarding a negative weld lead size, and instructions for determining the reference value range based on the negative weld lead size.
4. The system 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 system of claim 1 , wherein the instructions include instructions for receiving an input from the user regarding a positive weld lead size, and instructions for determining the reference value range based on the positive weld lead size.
6. The system of claim 1 , wherein the instructions include instructions for receiving an input from the user regarding a welding torch manufacturer, and instructions for determining the reference value range based on the welding torch manufacturer.
7. The system of claim 1 , wherein the instructions include instructions for receiving an input from the user regarding a welding torch model number, and instructions for determining the reference value range based on the welding torch model number.
8. The system of claim 1 , wherein the instructions include instructions for receiving an input from the user regarding a welding torch length, and instructions for determining the reference value range based on the welding torch length.
9. The system 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 system 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 system of claim 1 , wherein the weld secondary component is weld cabling.
12. The system of claim 1 , wherein the weld secondary component is a welding torch.
13. The system of claim 1 , wherein the weld secondary component is a rotary ground.
14. The system of claim 1 , wherein the weld secondary component is weld fixturing.
15. The system of claim 1 , wherein the weld secondary component is a welding workpiece.
16. The system of claim 1 , wherein the instructions comprise instructions for storing the determined value of the weld secondary parameter to the tangible machine-readable memory medium.
17. A system comprising:
a weld secondary component; and
a processor configured to execute instructions stored in a tangible machine-readable memory medium, the instructions comprising instructions for:
determining a value of a weld secondary parameter across the weld secondary component based on a sensed parameter;
receiving 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;
determining a reference value range based on the received input;
comparing the determined value to the determined reference value range; and
alerting 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 system 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.
19. The system of claim 17 , wherein the weld secondary component is weld cabling, a welding torch, a rotary ground, weld fixturing, or a welding workpiece.
20. The system of claim 17 , wherein the instructions comprise instructions for storing the determined value in the weld secondary parameter to a memory.
21. The system of claim 17 , wherein the sensed parameter is acquired via shorting of a welding torch tip to the weld secondary component.