Instructions / Assembly

Keywords:
Waveform Control Technology™
Output Modulation
W
aveform Control
Adaptive Control
Synergic Control
R
eal-Time
Waveform Control Technology
T
he inverter power source in the early 1980’s introduced a new
era in the development of arc welding power sources. They
affected the development of the full range of welding processes,
but in the specific areas of GMAW the results from intense
research and development are staggering.
The unique concept of Waveform Control Technology™ features
an inverter transformer power supply and a central processing
unit. The welding power output is produced by a high speed
amplifier. The software developed to drive the output is
enhanced to provide superior optimized welding output for a
variety of GMAW modes of metal transfer. The most notable of
these developments is the Surface Tension Transfer™, (STT™),
Constant Power™, and a variety of special pulsed spray transfer
modes of metal transfer.
The newer power sources feature the ability of the power source
to interact with the end-user and permit the worker to create
their own GMAW-P welding software program. Wave Designer
2000™ software is a commercially available Windows
®
software
program that provides real-time output control of the power
source. RS232 connectivity to the power source establishes a
communication link with the computer. For pulsed spray transfer,
short-circuiting transfer and STT, the output is modulated in
response to changes made to the components of the waveform.
The use of waveform control software allows further optimization
for a given mode of metal transfer. Templates for pulsed spray
transfer, short-circuiting transfer and STT are available for
adjustment to meet critical weld requirements. The objective for
the development may be to improve toe wetting action, reduce
dilution levels or to improve high travel speed performance of a
pulsed waveform. In any case, the interaction between the arc
performance and the adaptable output are central to the
success of Waveform Control Technology.
Data acquisition tools that are an important part of the software
allow the further ability to monitor the waveform during its
development.
The information collected permits alteration and
or final documentation of the suitability of the waveform for the
application.
Synergic control is designed to support all GMAW modes of
metal transfer. One knob control permits the welder to select the
wire feed speed, and then the voltage/trim value automatically
follows. For all of the synergic modes of metal transfer the con
-
cept of synergy eases the use of higher technology on the shop
floor.
The adaptive arc is an arc that quickly adjusts to changes in the
electrode extension to maintain the same arc length. The
o
bjective for adaptive control is to improve arc performance and
maintain finished weld quality.
Components of GMAW-P Waveform
Keywords:
Front Flank Ramp-up Rate
P
ercent Overshoot
Peak Current
Peak Time
Tail-out
Tail-out Speed
Step-off Current
Background Current
Pulse Frequency
Nine essential components are useful for manipulating the output
character of the GMAW-P waveform. The interaction of the
components determines the specific outcome character of the
waveform. Important in this basic understanding is the effect
that shielding gas (see shielding gases for GMAW on page 12),
electrode diameter, and electrode type have on the finished
weld.
The Wave Designer 2000™ graphical user interface provides a
visual image for the theoretical waveform. It is plotted on a
“Current vs. Time” grid which reproduces changes made to the
waveform. The changes made to a given pulsed wave
form
either add to, or subtract from, the area under the waveform. As
the area under the waveform increases, there will be an increase
in energy to the arc. The reverse is also true, when the area
under
the waveform decreases, the energy to the arc decreases.
I
nput Power
I
nverter
Waveform
G
enerator
High Speed
A
mplifier
A
rc
CPU - Central
P
rocessing
Unit
FIGURE
12: Wave Designer 2000 Pulse Editor
18
www.lincolnelectric.com
GMAW
Advanced Welding Processes for GMAW
Input Power
Arc
Waveform
Generator
High Speed
Amplifier
CPU - Central
Processing Unit
Inverter