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B-2

Appendix B

STT WAVE SHAPING PRINCIPLES

WAVE DESIGNER

STT Waveform Editor

Wire Feed Speed

Peak Amps

Tailout Speed

Pinch Start

Pinch | Peak

Peak Time

dV | dt detect

Backgrd Amps

14.00

1.0

.70

140

Edit

Start

About

Explain

Wave Designer Pro Off Line - stt.swf

500

400

300

200

100

File

Tools

Help

Off Line

Stand by

Status

read template2.map

27850057

.500

200

AMPERES

PINCH START

dV/dt CALCULATE

PEAK TIME

PEAK AMPS

TAILOUT
SPEED

BACKGROUND AMPS

TIME

B.2 STT OVERVIEW

Figure B-1 illustrates the variables of the STT welding process. Each of these variables can be
programmed into a weld table using the

Wave Designer

software. Figure B-2 shows how the

STT waveform and the primary variables produce a weld.

For more details on each of these variables, refer to

Primary STT Waveform Components

and

Secondary STT Waveform Components

in paragraphs B.5 and B.6 of this appendix.

FIGURE B-1. STT WAVEFORM PARAMETERS.

Содержание WAVE DESIGNER

Страница 1: ...e Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp Overshoot 26 4 33 4 21 40 100 3 0 1 2 250 20 600...

Страница 2: ......

Страница 3: ...ve Design Process 3 11 3 4 Downloading Wave Shapes 3 12 3 5 Autosave 3 13 ArcScope Section 4 4 1 Introduction 4 1 Troubleshooting Section 5 5 1 Overview 5 1 5 2 Wave Designer Troubleshooting Procedure...

Страница 4: ...that the Software is free of errors or limitations No warranty is made by Lincoln with respect to the Java Runtime software THE ABOVE WARRANTIES ARE THE ONLY WARRANTIES OF ANY KIND EITHER EXPRESSED O...

Страница 5: ...rademarks html ii not do anything harmful to or inconsistent with Sun s rights in the Java Marks and iii assist Sun in protecting those rights including assigning to Sun any rights acquired by License...

Страница 6: ...iv iv LICENSE INFORMATION WAVE DESIGNER...

Страница 7: ...ferent than those expected Some adjustments to procedures may be necessary to compensate for unique individual conditions When possible test all procedures duplicating actual field conditions 1 3 COMP...

Страница 8: ...reports to wavedesigner lincolnelectric com Refer to the Wave Designer Welcome screen for the applicable release version of the Wave Designer software package Wave Designer is a JAVA TM application a...

Страница 9: ...from your START window to start up the program Refer to Table 2 1 for alternate installation procedures On startup the Wave Designer screens in Figure 2 1 will be displayed NOTE If upgrading a previou...

Страница 10: ...s as follows 1 Disconnect the electrical power to the welding machine 2 Remove the control box LED display panel Figure 2 2 Be careful not to pull hard on the panel wiring harness 3 Locate the bottom...

Страница 11: ...that it uses alternate resources If you are not using infrared for printing or file sharing it is recommended that it be disabled To disable infrared and enable the serial port on COM 1 do the followi...

Страница 12: ...ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp Overshoot 26 4 33 4 21 40 100 3 0 1 2 250 20 600 Edit Start About Adapt Short End Wave Designer Pro Off Line pulse s...

Страница 13: ...e If a selected WFS is between two pre programmed workpoints the Power Wave will interpolate values for each of the welding variables The result is a precise and continuous range of welding control Re...

Страница 14: ...w for selecting a workpoint and an edit window for changing the listing of workpoint values For the Pulse Waveform Editor the workpoints are wire feed speeds The workpoint parameter peak voltage curre...

Страница 15: ...bar provides a scrolled listing of recent program events error conditions etc Use the arrow keys to scroll through the listings The status bar includes three system status indicators on line off line...

Страница 16: ...rms volts ohms amps etc for any stored waveform swf file Save Scope As Wave Designer Pro option only Use this option to save an open Scope Trace file under a different filename Save Scope Wave Designe...

Страница 17: ...ploaded Adaptive File Tools Print Help Search for Mode 12 NST3510C SWG Steel Pulse 035 Steel Argon CO2 Blends Mode 20 N45ST00C SWG Mig 3 045 Steel CO2 Mode 21 N45ST10C SWG Mig 3 045 Steel Argon CO2 Bl...

Страница 18: ...Amps Backgrd Amps Peak Time ms Backgrd Time Frequency Tailout Speed Ramp Overshoot Peak Voltage Adaptive Type Inductance Short Detect Volt Pinch Current Rise Rate Arc Restablish Volt End Amp End Time...

Страница 19: ...ection 3 3 7 SOFTWARE OPERATION WAVE DESIGNER Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp...

Страница 20: ...ly one workpoint is fixed checked Go Figure copies the workpoint sets the wave shape parameters for all other defined workpoints equal to those of the fixed workpoint This function should be used just...

Страница 21: ...hine setting is not equal to the selected workpoint value changes to the wave shape will be applied to the workpoint value nearest the welding machine setting The welding machine Trim encoder must be...

Страница 22: ...keyboard arrow keys to move the hot spot Press Ctrl and an arrow key to move the hot spot 10 times faster Use the F1 key to jump to the next hot spot Uncontrolled drag with the mouse can result in la...

Страница 23: ...ep can be found in the listed reference paragraphs 27850021 Set NO ADAPT Set ADAPT Save File to Disk Develop Next Workpoint A 4 2 Step 1 A 4 1 A 4 2 Step 2 A 4 2 Steps 3 4 A 4 2 Steps 5 6 7 A 4 2 Step...

Страница 24: ...pload from a welding machine If a weld file is corrupted you will not be able to upload the machine s weld mode directory You can download up to ten custom waveforms to the weld mode directory The ass...

Страница 25: ...les with factory default files for download b Last uploaded files Merges selected files with weld mode directory last uploaded from a welding machine Overwrites modes 155 through 164 if like mode I D...

Страница 26: ...3 14 Section 3 SOFTWARE OPERATION WAVE DESIGNER...

Страница 27: ...tout of the active ArcScope graphics 2 Toggle Options Live Update and Condense are toggled on and off with the mouse Additional information about the Live Update and Condense options is provided in pa...

Страница 28: ...application is running The Let Go option disables the Pause function Configure Use the Scope Configuration window to select the power source measurements for the graphical display area Centerline Sel...

Страница 29: ...application File Open Scope Trace Use the Open Scope Trace option to open a saved scope trace data file Section 4 4 3 ARCSCOPE WAVE DESIGNER File Open Waveform Ctrl O Ctrl S Ctrl Q Save Waveform As S...

Страница 30: ...4 4 Section 4 ARCSCOPE WAVE DESIGNER...

Страница 31: ...gner program with a DOS console window for diagnostic messages in the background a From your Windows Start screen move the mouse over the Wave Designer icon b Right click the mouse and select Properti...

Страница 32: ...5 2 Section 5 TROUBLESHOOTING WAVE DESIGNER...

Страница 33: ...ve shape parameters effect Mode welding A 4 Pulse Wave Design Process Flowchart and step by step descriptions of the pulse wave design process A 5 Primary Pulse Waveform How peak current peak time fre...

Страница 34: ...Adaptive A 2 GMAW PULSE OVERVIEW Figure A 1 illustrates the variables of the GMAW P welding process Each of these variables can be programmed into a weld table using the Wave Designer software Figure...

Страница 35: ...r force are controlled by peak current and peak time From time T4 to T5 Tailout current controls the heat input to and agitation of the weld puddle Shorter tailout contributes less heat to the weld Th...

Страница 36: ...paragraph A 4 Note This step must be performed with the Trim set equal to 1 0 on the Power Wave machine A 3 2 NON ADAPTIVE MODE In non adaptive mode the Power Wave does not adapt the pulse variables t...

Страница 37: ...ented Where an editing function is described as optional and you choose not to perform the edit function proceed to the next edit function in the design process FIGURE A 4 PROCESS FLOWCHART Appendix A...

Страница 38: ...en custom weld modes can be downloaded to the welding machine You cannot upload a custom weld from the welding machine but you can overwrite any or all of your allotted weld file memory locations b In...

Страница 39: ...wave shaping Thereafter refer to the following wave shaping procedure 1 Select a Workpoint a Select a workpoint from the Wire Feed Speed pulldown menu The first workpoint selected should be in the mid...

Страница 40: ...of the trim adjustment capability The welding machine s trim control allows the welder to adjust the arc length between 0 5 to 1 5 50 to 150 times the established arc length adjustment factor c Mainta...

Страница 41: ...Editor screen to view the Adapting Stickout screen Click on the arrow in the adaptive type box to display the adaptive types listing b Select each adaptive type in turn and perform a trial weld After...

Страница 42: ...Strike Peak Time Strike Peak Amps Open Circuit Volt 48 0 2 0 28 0 50 50 550 0 150 27850035 STRIKE PEAK AMPS STRIKE PEAK TIME START TIME ARC STRIKE OPEN CIRCUIT VOLTS AVERAGE START AMPS START VOLTS Op...

Страница 43: ...ULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER AMPS VOLTS ARC REESTABLISH VOLTS SHORT DETECT VOLTS PINCH CURRENT RISE PLATE 27850036 Shorting Control Shorting Control 5 55 18 15 For Wire Feed Speed Short...

Страница 44: ...ollowing parameter descriptions A 12 Appendix A PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER 27850037 End Conditioning End Conditioning For Wire Feed Speed End Amp End Time Amp Time 50 550 0 2 5 1375 0...

Страница 45: ...ER WIRE FEED SPEEDS WORKPOINT VARIABLE WorkPoint Editor WorkPoint Editor 1 0 2 3 4 5 6 7 8 9 10 11 80 700 80 700 110 700 150 700 205 300 400 600 inch min meter min Go Figure FIXED VALUE INTERPOLATED E...

Страница 46: ...etach the weld droplet from the electrode and propel it across the arc Transition current is the current level required to achieve weld droplet formation In order to achieve weld droplet transfer the...

Страница 47: ...average current levels FIGURE A 7 FREQUENCY Appendix A A 15 PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER 27850040 AVERAGE CURRENT AVERAGE CURRENT BACKGROUND CURRENT BACKGROUND CURRENT T1 T1 T2 T2 T3 T3...

Страница 48: ...ore likely to short circuit the electrode to the work A 6 4 TAILOUT TIME The tailout time is the duration of tailout Longer tailout times maintain the system heat longer Shorter tailout times can forc...

Страница 49: ...working properly with the welder We recommend using a standard waveshape such as mode 5 to confirm that the welding system performs under normal conditions before attempting to develop waveshapes 1 Se...

Страница 50: ...set the Peak Voltage to obtain the desired arc length at the 1 00 trim setting Adapting Stickout Adapting Stickout For Wire Feed Speed No Adapt Maintain constant wire extension 27850043 Adaptive Maint...

Страница 51: ...0 150 1200 205 300 400 600 inch min meter min Go Figure 28750032 6 The Start Short and End windows can be adjusted at this time to optimize the starting shorting and ending routines Start Control Puls...

Страница 52: ...ps Backgrd Amps Backgrd Time Ramp Overshoot 8 3 20 25 100 1 5 1 4 250 0 600 Edit 150 27850045 Our Experiment At the higher wire feed speed we needed more heat to melt the added wire We took the backgr...

Страница 53: ...e checked its performance across the range of wire feed speeds 13 The specific wire feed speed points of the program are now developed in the range of 150 in min to 300 in min Check the full range of...

Страница 54: ...A 22 Appendix A PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER...

Страница 55: ...Transfer How WFS and wave shape parameters effect welding B 4 STT Wave Design Process Flowchart and step by step descriptions of the STT wave design process B 5 Primary STT Waveform How peak current b...

Страница 56: ...27850057 500 60 200 AMPERES PINCH START dV dt CALCULATE PEAK TIME PEAK AMPS TAILOUT SPEED BACKGROUND AMPS TIME B 2 STT OVERVIEW Figure B 1 illustrates the variables of the STT welding process Each of...

Страница 57: ...ackground Ball Time current is reduced for approximately 0 75 milliseconds From time T2 to T3 High current is applied to speed the transfer of molten metal to the Pinch weld puddle A dV dt calculation...

Страница 58: ...6 7 Time 27850063 T T T 1 2 T0 T1 A background current between 50 and 100 Amps is delivered to the arc prior to shorting of the electrode to the weld puddle Background current is a steady state curren...

Страница 59: ...separation has occurred but at a very low current T5 T6 Immediately following separation of the electrode from the weld puddle peak current occurs Peak current is a period of high arc current The ele...

Страница 60: ...you perform all editing functions in the order presented Where an editing function is described as optional and you choose not to perform the edit function proceed to the next edit function in the des...

Страница 61: ...en custom weld modes can be downloaded to the welding machine You cannot upload a custom weld from the welding machine but you can overwrite any or all of your allotted weld file memory locations b In...

Страница 62: ...o get thoroughly acquainted with wave shaping Thereafter refer the following wave shaping procedure 1 Select a Workpoint a Select a workpoint from the Wire Feed Speed pulldown menu The first workpoint...

Страница 63: ...bout 5 8 in to 3 4 in 16 mm to 19 mm electrical stickout c While welding a trial weld bead adjust the waveform variables peak current background current tailout etc to achieve a desired droplet transf...

Страница 64: ...ll Formation Start Volt Start Time 90 42 00 750 1 0 23 00 700 20 0 STRIKE I Open circuit voltage Sets the power source output voltage for the torch idle condition the welding machine is on but not wel...

Страница 65: ...op the second workpoint in the same manner as the first Appendix B B 11 STT WAVE SHAPING PRINCIPLES WAVE DESIGNER WorkPoint Editor WorkPoint Editor 1 0 2 3 90 170 200 225 inch min meter min Go Figure...

Страница 66: ...ing the arc length If set too high long arc lengths will inhibit travel speed Setting this level too low will cause instability and wire stubbing In practice this current level should be adjusted for...

Страница 67: ...5 LONG OPTIMUM CONTACT TIP TO WORK DISTANCE SHORT 24850065 OPTIMUM LOW HIGH ADJUST BEAD SHAPE USING BACKGROUND CURRENT NOTE Applications using 100 CO2 require less background current than similar proc...

Страница 68: ...rrent must exceed background current B 6 2 PINCH PEAK Pinch Peak is the ratio of maximum pinch current to peak current This parameter is used to establish the desired maximum pinch current value B 6 3...

Страница 69: ...lop more workpoints for practice Before starting the waveshape development process confirm that the consumables are working properly with the welder We recommend using a standard waveshape such as mod...

Страница 70: ...HAPING PRINCIPLES WAVE DESIGNER Our Experiment The weld produced by this setting is too hot We burned through the 16 gauge fillet The arc is too long and is producing too much spatter First we reduced...

Страница 71: ...puter System Requirements 1 1 Control Board Dip Switch Settings 2 2 Current Background A 15 B 4 B 13 Peak A 14 B 5 B 12 Transition A 14 D Data Table Waveform 3 6 Dip Switch Settings Control Board 2 2...

Страница 72: ...n B 6 Process Wave Design 3 11 Product Overview 1 1 Pulse Frequency A 15 Pulse Wave Design Process 3 11 Pulse Wave Shaping Principles A 1 R Ramp Up Rate A 16 S Secondary Waveform Parameters Pulse A 16...

Страница 73: ...1 Start A 10 W Wave Design Process Pulse 3 11 Wave Design Process STT B 6 Wave Shaping Pulse A 1 Wave Shaping STT B 1 Wave Designer Operation 3 2 Waveform Data Table 3 6 Waveform Editor Window 3 2 Wel...

Страница 74: ...INDEX Index 4 WAVEDESIGNER...

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