DESCRIPTION
WELDING MACHINE
TECHNICAL FIELD
The present invention relates to an apparatus which processes a
workpiece by creating an arc. The invention relates more particularly
to a welding machine equipped with a programmable device such as a
CPU so as to perform digital control.
BACKGROUND ART
Welding machines and other similar machines create an arc
using an electrode, and melt a base material, which is the workpiece.
These machines generally include an output control circuit, a gas
control circuit, and a start circuit. The output control circuit controls
the current and voltage of the arc created between the electrode and
the base material. The gas control circuit controls the shielding gas
which protects the arc from the atmosphere. The start circuit
promotes the creation of an arc. Consumable electrode arc welding
machines further include a feed control circuit for controlling the feed
of a welding wire, which is the consumable electrode.
There is a growing demand for more sophisticated welding
machines in recent years. To achieve this, each of the output control
circuit, the gas control circuit, and the start control circuit has been
composed of a programmable device such as a central processing unit
(CPU) and been controlled by software. These welding machines are
now widely used and known as digital control welding machines.
Digital control welding machines provide various welding
methods, and allow operators to set detailed conditions in each welding
method. The welding machines can, for example, be operated in a DC
welding mode when the workpiece is made of iron or stainless, and in
an AC welding mode when the workpiece is made of aluminum.
The welding machines control a pulse welding method in which
the output has a pulse waveform according to the state of the
workpiece, and also control the welding according to many parameters.
The parameters include the pulse frequency and pulse width when the
pulse welding is performed! and the output current and gas flow time,
which change according to the thickness of the workpiece.
Some of the digital control welding machines are known to
include an encoder called a jog dial and a light emitting diode (LED)
display device to set these parameters (see, for example, Patent
Literature l). These parameters are generally set according to the
knowledge and experience of welding operators or the performance
conditions written in instructions.
A conventional arc welding machine including a jog dial and an
LED display device will be described as follows with reference to Fig. 5.
Fig. 5 shows a schematic configuration of the conventional welding
machine.
In Fig. 5, the arc welding machine includes operating unit 4 and
LED display unit 3. Operating unit 4 includes jog dial 1 and switches
2, which are used by operators to set conditions. LED display unit 3
displays alphanumeric characters. The arc welding machine further
includes controlling unit 5, welding controlling unit 6, output drive
circuit 7, shielding-gas drive circuit 8, start-device drive circuit 9, and
wire-feed-motor drive circuit 10. Controlling unit 5 controls welding
operation by modifying conditions according to welding parameters set
by operators using operating unit 4. Welding controlling unit 6
controls welding operation based on a command from controlling unit 5.
Output drive circuit 7 is controlled by welding controlling unit 6.
The following is a description of the operation of the
conventional arc welding machine having the above-described
structure.
In general, arc welding machines are classified into two types,
namely, consumable and non-consumable electrode arc welding
machines. The two types of machines have almost the same welding
condition items except that consumable electrode arc welding
machines set the speed of a wire feed motor, which feeds a welding wire
to the welding position. Specific examples of the welding condition
items include the choice between AC output and DC output, welding
current value, gas flow time, and whether or not to perform pulse
welding.
The factory default values of the arc welding machine are set as
welding condition parameters. The operator selects welding condition
items by operating switches 2, and sets numerical values
corresponding to the selected welding condition items by operating jog
dial 1. As a result, controlling unit 5 modifies the setting of the
welding conditions. The set numerical values of the welding condition
items are displayed on LED display unit 3, so that the operator can
visually recognize them. Thus, before starting welding, the operator
sets the value of each welding condition item, thereby setting the
conditions required for the welding. The setting values determined by
controlling unit 5 are transmitted to welding controlling unit 6.
Welding controlling unit 6 operates output drive circuit 7,
shielding-gas drive circuit 8, and start-device drive circuit 9 according
to the received setting values. Thus, welding is performed according
to the welding conditions set by the operator. The conventional
welding machine allows the operator to set precise welding conditions
by entering digital numerical values.
In the conventional welding machine, however, many welding
condition items including the choice of welding method and welding
current are set according to the knowledge and experience of operators
or reference materials such as written instructions. This takes a lot
of time to set the conditions, and only expert operators can set them
appropriately.
Citation List
Patent Literature
PTL 1*. Design Registration No. 1274142
SUMMARY OF THE INVENTION
To solve the above-described problems, the present invention is
directed to provide an arc welding machine used in connection with a
welding torch and includes the following: a setting unit, a storing unit,
a controlling unit, a first display unit, and a second display unit. The
setting unit sets information about an object to be welded. The
storing unit stores a plurality of associated groups each consisting of:
information about an object to be welded; the value of a first welding
condition item settable in the welding machine; and the value of a
second welding condition item non-settable in the welding machine.
The controlling unit selects the value of at least one first welding
condition item and the value of at least one second welding condition
item from the storing unit based on the information about the object to
be welded set by the setting unit. The first display unit displays the
value of the at least one first welding condition item selected by the
controlling unit. The second display unit displays the value of the at
least one second welding condition item selected by the controlling
unit.
Thus, the welding machine of the present invention allows the
operator to enter information about an object to be welded, thereby
providing optimum welding conditions for the object. The machine
includes a display unit which provides the operator with information
that is non-settable in the welding machine but is important for
successful welding. As a result, the welding machine has high
welding performance.
BRIEF DESCRIPTION OF DRAWINGS
Fig. 1 is a schematic configuration of a welding machine
according to a first exemplary embodiment of the present invention.
Fig. 2 is an external view of the welding machine according to
the first exemplary embodiment.
Fig. 3 is a schematic configuration of an operating unit of the
welding machine according to the first exemplary embodiment.
Fig. 4 shows an example of how conditions are set, and an
example of how the conditions are displayed on the welding machine
according to the first exemplary embodiment.
Fig. 5 is a schematic configuration of a conventional welding
machine.
DESCRIPTION OF EMBODIMENT
An embodiment of the present invention will be described as
follows with reference to drawings. In these drawings, the same
components are denoted by the same reference numerals, and hence,
the description thereof may be omitted.
FIRST EXEMPLARY EMBODIMENT
A welding machine of the present exemplary embodiment will
be described as follows with reference to Figs. 1 to 4. Fig. 1 is a
schematic circuit configuration of the welding machine. Fig. 2 is an
external view of the welding machine. Fig. 3 is a schematic
configuration of an operating unit of the welding machine. Fig. 4
shows an example of how conditions are set, and an example of how the
conditions are displayed on the welding machine.
The present exemplary embodiment describes an arc welding
machine which creates an arc between a welding electrode and an
object to be welded. The welding machine has an external appearance
shown in Fig, 2, and includes, at its front, setting unit 11 and condition
modifying unit 16, both of which will be described later. Setting unit
11 and condition modifying unit 16 have the structures shown in Fig. 3.
In the welding machine shown in Fig. 1, setting unit 11 includes
jog dial 1 as an encoder and switches 2. Jog dial 1 and switches 2 are
operated by the operator to set information about an object to be
welded and also to set welding conditions.
The welding machine further includes storing unit 12, which
stores a plurality of associated groups. Each group consists of the
following: information about an object to be welded; a first welding
condition item settable in the welding machine; a second welding
condition item non-settable in the welding machine; the value of the
first welding condition item; and the value of the second welding
condition item.
The welding machine further includes controlling unit 13, first
display unit 14, and second display unit 15. Controlling unit 13 has a
simplified setting function of selecting the value of at least one first
welding condition item and the value of at least one second welding
condition item from storing unit 12 based on the information about the
object to be welded set by setting unit 11. First display unit 14
displays the value of the at least one first welding condition item
selected by controlling unit 13. Second display unit 15 displays the
value of the at least one second welding condition item selected by
controlling unit 13. First and second display units 14 and 15 can be,
for example, an LED indicator or a liquid crystal panel for displaying
alphanumeric characters. In Fig. 3, first display unit 14 is an LED
indicator, and second display unit 15 is a liquid crystal panel.
The same components as those in the conventional welding
machine shown in Fig. 5 are denoted by the same reference numerals,
and are not described in detail again.
Although not described here, consumable electrode arc welding
machines further include a wire-feed-motor drive circuit for feeding a
wire.
The welding machine of the present exemplary embodiment
differs from the conventional welding machine described in
BACKGROUND ART in having storing unit 12; controlling unit 13 for
selecting the values of first and second welding condition items from
storing unit 12; and the first and second display units. Storing unit
12 stores a plurality of associated groups each consisting of the
following: information about an object to be welded; the value of a first
welding condition item settable in the welding machine! and the value
of a second welding condition item non-settable in the welding machine.
Controlling unit 13 selects the value of the at least one first welding
condition item and the value of the at least one second welding
condition item from storing unit 12 based on the information about the
object to be welded set by setting unit 11. First display unit 14
displays the value of the at least one first welding condition item
selected by controlling unit 13. Second display unit 15 displays the
value of the at least one second welding condition item selected by
controlling unit 13.
The following is a description of the operation of the welding
machine having the above-described structure. The operator of the
welding machine enters information about the object to be welded by
operating jog dial 1 and switches 2 of setting unit 11. Specific
examples of the information about the object to be welded include the
material and thickness of the object, the joint shape of the welding
portion, and welding posture. As shown in Fig. 4, the operator first
presses switch 1 for mode selection as shown in operation (l). As a
result, the input mode of the object to be welded is selected. The
operator then enters the following information about the object to be
welded: material, thickness, joint shape, and welding posture in that
order. Second display unit 15 displays the information as "material",
"thickness", "joint", and "posture", respectively, as shown in operations
(2) through (5) in Fig. 4. The operator then presses switch 3 to
display welding conditions on the second display unit as shown in
operation (6). The welding conditions, which are selected from the
entered conditions of the object to be welded, are non-settable in the
welding machine.
Storing unit 12 stores a plurality of groups each consisting of
the following: information about an object to be welded; the value of a
welding condition item that is settable in the welding machine and
that is associated with the information about the object; and the value
of a welding condition item that is non-settable in the welding machine
and that is associated with the information about the object. The
values of these items, which are experimentally determined and
pre-stored in storing unit 12, are optimum welding conditions for the
object to be welded whose information has been entered by the
operator.
Assume that the operator of the welding machine enters
information about an object to be welded by operating setting unit 11.
In this case, controlling unit 13 selects, from storing unit 12, welding
conditions that are settable in the welding machine and that agree
with the entered information about the object to be welded, and the
values of the parameters of the welding conditions. Controlling unit
13 then sets these welding conditions in the welding machine so that
first display unit 14 displays the welding conditions. Controlling unit
13 further selects, from storing unit 12, welding conditions that are
non-settable in the welding machine and that agree with the entered
information about the object to be welded. Second display unit 15
displays the welding conditions.
Specific examples of the welding condition items that are
settable in the welding machine and that are displayed on first display
unit 14 include the following: welding method, welding current,
pre-flow time, after-flow time, the choice of the presence or absence of
a pulse, pulse current, pulse frequency, pulse width, the choice of the
presence or absence of a crater, initial current, crater current, up-slope
time, down-slope time, AC waveform, AC frequency, EN ratio, AC/DC
ratio, and AC/DC frequency in the case of a non-consumable electrode
arc welding machine. In the case of a consumable electrode arc
welding machine, on the other hand, the specific examples further
include welding voltage.
After welding is actually performed, the operator sometimes
wants to modify a welding condition settable in the welding machine.
In this case, the operator can modify the value of a welding condition
item that is settable in the welding machine and that is displayed on
first display unit 14 by using condition modifying unit 16 shown in Fig.
1. To achieve this, the operator selects the welding condition item to
be modified by pressing one of condition switches 18 (one of conditions
SW1 to SWn) corresponding to the welding condition item settable in
the welding machine. The operator then modifies the value by
operating jog dial 17 for modifying welding conditions.
Specific examples of the welding condition items that are
non-settable in the welding machine and that are displayed on second
display unit 15 include the following^ shielding gas flow rate, filler
wire diameter, non-consumable electrode diameter, and the angle of
the tip of the non-consumable electrode. These items, which cannot
be directly set in the welding machine, are important parameters for
successful welding, but are difficult parameters for inexperienced
operators to set.
The values displayed on first display unit 14 are set as welding
conditions by controlling unit 13 and transmitted to welding
controlling unit 6. The operator prepares for welding according to the
welding condition items non-settable in the welding machine and the
values of these items which are displayed on second display unit 15.
Assume here that second display unit 15 displays shielding gas flow
rate, filler wire diameter, non-consumable electrode diameter, and the
angle of the tip of the non-consumable electrode as shown in Fig. 4. In
this case, the operator sets the gas flow rate to 10 L by operating a gas
regulator disposed outside the welding machine. The operator also
attaches a 1.6 mm-diameter filler to an unillustrated filler feeder.
The operator also attaches a non-consumable electrode having a
diameter of 2.4 mm and a tip angle of 30 degrees to an unillustrated
welding torch.
After the completion of the setting of the welding condition
items settable and non-settable in the welding machine, the actual
welding is started.
If the value of an item that is settable in the welding machine
and that is displayed on first display unit 14 is modified by operating
condition switches 18 (conditions SW1 through SWn) or jog dial 17 of
condition modifying unit 16, controlling unit 13 deletes the
information displayed on second display unit 15.
The reason to delete the information displayed on second
display unit 15 is as follows. The information displayed on first and
second display units 14 and 15 are optimum values for the object to be
welded whose information has been entered by the operator to setting
unit 11 of the welding machine. If the value of even one of the welding
condition items displayed on first display unit 14 is modified, the
values of the welding condition items displayed on second display unit
15 are not optimum any more for the object to be welded. Therefore,
second display unit 15 displays the new values of the welding condition
items that have been modified to be optimum for the object to be
welded.
As described above, the welding machine of the present
exemplary embodiment allows the operator to enter information about
an object to be welded by using jog dial 1, switches 2, and first display
unit 14. As a result, the machine provides optimum welding
conditions for the object selected from storing unit 12. Thus, the
welding conditions settable in the welding machine are automatically
set based on the information about the object to be welded.
As a result, operators who are inexperienced in welding
conditions can enter information about an object to be welded that is
settable in the welding machine while checking with eyes.
Consequently, appropriate welding conditions are selected from storing
unit 12 and set in the welding machine, making the welding machine
more user-friendly.
Furthermore, welding conditions non-settable in the welding
machine are displayed on second display unit 15 so that the operator
can see them. As a result, operators who are inexperienced in welding
conditions can understand information that is non-settable in the
welding machine but is important for successful welding. The
welding machine provides better welding performance based on the
information entered by the operator, becoming more user-friendly.
The present exemplary embodiment uses separate display
units: first and second display units 14 and 15. Alternatively, one
display unit such as a large LCD may be used.
The present exemplary embodiment uses two jog dials: jog dial 1
in setting unit 11 and jog dial 17 in condition modifying unit 16.
Alternatively, it is possible not to provide jog dial 17 in condition
modifying unit 16, but to provide only jog dial 1 in setting unit 11 to
modify the information displayed on first display unit 14.
The welding machine of the present invention, which is used in
connection with a welding torch, includes setting unit 11, storing unit
12, controlling unit 13, first display unit 14, and second display unit 15.
Setting unit 11 sets information about an object to be welded. Storing
unit 12 stores a plurality of associated groups each consisting of the
following; information about an object to be welded! the value of a first
welding condition item settable in the welding machine! and the value
of a second welding condition item non-settable in the welding machine.
Controlling unit 13 selects the value of at least one first welding
condition item and the value of at least one second welding condition
item from storing unit 12 based on the information about the object to
be welded set by setting unit 11. First display unit 14 displays the
value of the at least one first welding condition item selected by
controlling unit 13. Second display unit 15 displays the value of the
at least one second welding condition item selected by controlling unit
13.
With this structure, the welding machine allows the operator to
enter information about an object to be welded, thereby providing
optimum welding conditions for the object. Furthermore, second
display unit 15 provides the operator with information that is
non-settable in the welding machine but is important for successful
welding. As a result, the welding machine has high welding
performance.
In the welding machine of the present invention, controlling
unit 5 may alternatively select at least one second welding condition
item and the value of this item from storing unit 12 based on the
information about the object set by setting unit 11. Second display
unit 15 may display the selected item and value.
With this structure, welding conditions that are non-settable in
the welding machine and that are suitable for the information about
the object are selected from storing unit 12 and displayed by setting
the information about the object. Thus, the welding conditions
non-settable in the welding machine can be automatically displayed
based on the information about an object to be welded.
The welding machine of the present invention may further
include condition modifying unit 16 for modifying the value of the at
least one first welding condition item displayed on first display unit 14.
If the value of this item is modified, the content displayed on second
display unit 15 may be deleted.
With this structure, if the value of at least one welding
condition item is modified, second display unit 15 does not continue to
display non-optimum values for the object to be welded. This
prevents the welding machine from providing non-optimum welding
conditions.
In the welding machine of the present invention, the at least
one second welding condition item may include at least one of the
following-- shielding gas flow rate, filler wire diameter, non-consumable
electrode diameter, and the angle of the tip of the non-consumable
electrode.
With this structure, operators who are inexperienced in welding
conditions can enter information about an object to be welded that is
settable in the welding machine while checking with eyes.
Consequently, appropriate welding conditions are selected from storing
unit 12 and set in the welding machine, making the welding machine
more user-friendly.
In the welding machine of the present invention, the at least
one first welding condition item may include at least one of the
following: welding method, welding current, welding voltage, pre-flow
gas time, after-flow time, the choice of the presence or absence of a
pulse, pulse current, pulse frequency, pulse width, the choice of the
presence or absence of a crater, initial current, crater current, up-slope
time, down-slope time, AC waveform, AC frequency, EN ratio, AC/DC
ratio, and AC/DC frequency.
This structure simplifies the setting of welding conditions,
making the welding machine more user-friendly.
In the welding machine of the present invention, the
information about an object to be welded may include at least one of
the following'- the material or thickness of the object to be welded, joint
shape, and welding posture.
This structure allows optimum welding conditions to be set for
the object to be welded whose information has been entered by the
operator. The optimum welding conditions are experimentally
determined and pre-stored in storing unit 12. As a result, operators
who are inexperienced in welding conditions can understand
information that is non-settable in the welding machine but is
important for successful welding. The welding machine provides
better welding performance based on the information entered by the
operator, becoming more user-friendly.
In the welding machine of the present invention, first display
unit 14 and second display unit 15 may alternatively be formed as one
display unit.
With this structure, operators can view a list of necessary
information on one display unit, making the welding machine more
user-friendly.
INDUSTRIAL APPLICABILITY
The welding machine of the present invention allows operators
to set welding conditions easily, thereby becoming more user-friendly.
This welding machine is useful to industrial welding under various
welding conditions.
REFERENCE MARKS IN THE DRAWINGS
1 jog dial
2 switch
3 LED display unit
4 operating unit
5 controlling unit
6 welding controlling unit
7 output drive circuit
8 shielding-gas drive circuit
9 start-device drive circuit
10 wire_feed-motor drive circuit
11 setting unit
12 storing unit
13 controlling unit
14 first display unit
15 second display unit
16 condition modifying unit
17 jog dial
18 condition switch (condition SW1 ... condition SWn)
We Claim:

1. A welding machine used in connection with a welding torch, the
welding machine comprising:
a setting unit for setting information about an object to be
welded;
a storing unit for storing a plurality of associated groups each
consisting of:
information about an object to be welded!
a value of a first welding condition item settable in the
welding machine; and
a value of a second welding condition item non-settable
in the welding machine!
a controlling unit for selecting a value of at least one first
welding condition item and a value of at least one second welding
condition item from the storing unit based on the information about
the object to be welded set by the setting unit;
a first display unit for displaying the value of the at least one
first welding condition item selected by the controlling unit; and
a second display unit for displaying the value of the at least one
second welding condition item selected by the controlling unit.
2. The welding machine of claim 1, wherein
the controlling unit selects at least one second welding
condition item and a value of the at least one second welding condition
item from the storing unit based on the information about the object to
be welded set by the setting unit, and
the second display unit displays the at least one second welding
condition item and the value of the at least one second welding
condition item selected by the controlling unit.
3. The welding machine of claim 1 or 2, further comprising:
a condition modifying unit for modifying the value of the at1
least one first welding condition item displayed on the first display
unit, wherein
if the value of the at least one first welding condition item
displayed on the first display unit is modified, a content displayed on
the second display unit is deleted.
4. The welding machine of claim 1 or 2, wherein
the at least one second welding condition item includes at least
one of following: shielding gas flow rate, filler wire diameter,
non-consumable electrode diameter, and the angle of a tip of the
non-consumable electrode.
5. The welding machine of claim 1 or 2, wherein
the at least one first welding condition item includes at least;
one of following: welding method, welding current, welding voltage,
pre-flow gas time, after-flow time, a choice of presence or absence of a
pulse, pulse current, pulse frequency, pulse width, a choice of presence
or absence of a crater, initial current, crater current, up-slope time,
down-slope time, AC waveform, AC frequency, EN ratio, AC/DC ratio,
and AC/DC frequency.
6. The welding machine of claim 1 or 2, wherein
the information about the object to be welded includes at least
one of following: a material or thickness of the object to be welded,
joint shape, and welding posture.
7. The welding machine of claim 1, wherein
the first display unit and the second display unit are formed as
one display unit.

A welding machine which is used in connection with a welding
torch includes the following: a setting unit for setting information
about an object to be welded; a storing unit for storing a plurality of
associated groups each consisting of: information about an object to be
welded; the value of a first welding condition item settable in the
welding machine; and the value of a second welding condition item
non-settable in the welding machine; a controlling unit for selecting
the value of at least one first welding condition item and the value of at
least one second welding condition item from the storing unit based on
the information about the object to be welded set by the setting unit; a
first display unit for displaying the value of the at least one first
welding condition item selected by the controlling unit; and a second
display unit for displaying the value of the at least one second welding
condition item selected by the controlling unit. The welding machine
allows the operator to set welding conditions very easily.