Lincoln-electric IM649 Wave Designer User Manual

Wave DesignerTMSOFTWARE OPERATOR’S MANUALIM649May, 1999Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety

FIGURE 2-1.WAVE DESIGNERSTARTUP SCREEN.2-2 Section 2SOFTWARE INSTALLATIONWAVE DESIGNERLincoln Electric Wave Designer Version 1.0Copyright © 1998 The

Section 2 2-3SOFTWARE INSTALLATIONWAVE DESIGNERSW1SW21122334455667788ONONCONTROLBOXCONTROLBOARD27850003FRONTPA N ELPOWERSOURCERS232CABLECOMPUTERSYSTE

2.4 EQUIPMENT/SOFTWARE STARTUPWhen the Wave Designer software installation is complete, Wave Designer is listed among theprograms you can start up f

3.1 SYNERGIC WELDING AND WORKPOINTSPrior to using Wave Designer it is important to have a good understanding of the concepts ofsynergic welding an

3.2 WORKING IN WAVE DESIGNER3.2.1 WAVEFORM EDITOR WINDOWRefer to the Waveform Editor window in Figure 3-2 and the related usage instructions.FI

Section 33-3SOFTWARE OPERATIONWAVE DESIGNER5. Optional Windows The optional window buttons open additional windows used duringwave shaping. Optional

3-4 Section 3SOFTWARE OPERATIONWAVE DESIGNER3.2.2 WAVEFORM EDITOR TOOL BARThere are four menu selections available on the pulse waveform editor too

3.2.2.2 TOOLS MENUThe Tools menu includes waveform displayoptions and other tools required to operateWave Designer. The Tools menu optionsinclude the

3.2.2.3 PRINT MENUPrint menu options enable you to print out a waveform display, ArcScope screen, or tabularwaveform data listing as shown below. Th

3.2.3 EDITING AND SELECTING WORKPOINTSFor each custom welding application, unique wave shapes are developed for specific workpointswithin the range o

3.2.3.1 EDITING WORKPOINTSClicking on the Edit button in the waveform Editor window opens a Workpoint Editor window. TheWorkpoint Editor window displ

3.2.3.2 SELECTING WORKPOINTSClicking on the workpoint display box in the waveform Editor window opens a Workpointpulldown menu. The pulldown menu dis

3.2.4 EDITING VARIABLE PARAMETERSThe following is a summary of the different methods available for changing (editing) parametervalues on the Waveform

Section 3 3-11SOFTWARE OPERATIONWAVE DESIGNER3.3 WAVE DESIGN PROCESSThe wave design process is a series of operations that allows you to quickly mo

3-12 Section 3SOFTWARE OPERATIONWAVE DESIGNER3.4 DOWNLOADING WAVE SHAPESThe Power Wave stores wave shapes in the welding machine controller memory.

Section 3 3-13SOFTWARE OPERATIONWAVE DESIGNER2. Select a blank Mode or a defined Mode for overwrite by clicking on a box to the left of theModes lis

3-14 Section 3SOFTWARE OPERATIONWAVE DESIGNER

4.1 INTRODUCTIONThe following describes the ArcScope application included with Wave Designer Pro. TheArcScope application provides oscilloscope type

6. Status Bar The status bar provides a scrolled listing of recent Wave Designer programoperations, error conditions, etc., and three operational stat

File | Save Scope: Use the Save Scope option tosave the scope trace data in ASCII text format for usein a word editor or spreadsheet data processingap

WAVE DESIGNERiTABLE OF CONTENTSPageLicense Information ...

4-4 Section 4ARCSCOPEWAVE DESIGNER

5.1 OVERVIEWWave Designer troubleshooting is limited to the software application. If the welding machinedoes not respond, recheck the interface conne

5-2 Section 5TROUBLESHOOTINGWAVE DESIGNER

A.1 APPENDIX OVERVIEWThis appendix provides a series of discussions on pulse wave shaping principles and thedevelopment of custom GMAW pulse wavefor

A-2 Appendix APULSE WAVE SHAPING PRINCIPLESWAVE DESIGNERPulse Waveform EditorWire Feed SpeedRamp Up RatePeak AmpsPeak Time msTailout TimeTailout Spee

Appendix A A-3PULSE WAVE SHAPING PRINCIPLESWAVE DESIGNER• From time T1 to T2: Background current maintains an arc, and a weld bead starts toform.• Fr

A.3 ADAPTIVE AND NON-ADAPTIVE MODETo proficiently develop welding procedures using Wave Designer, the key concept of Adaptiveversus Non-Adaptive w

A.4 PULSE WAVE DESIGN PROCESSThe Wave Designer software interfaces with the welding machine controller to permit real timecommunication of pulse wave

A.4.1 SELECTING A STARTING WAVE SHAPEWhen customizing a waveform for a specific welding application, we recommend that you use awaveform in an existi

NOTE: You can edit one or more workpoints to values other than the defaults.However, the listing of wire feed speeds displayed must be the same orincr

By clicking the acceptance button or installing the software, you are consenting to be bound by and are becominga party to this agreement. If you do n

2. Open the Adaptive Loop / Find the Optimal Arc CharacteristicsUse the following weld trials and adjustment sequence to tune the selected waveform fo

3. Close the Adaptive Loop / Adjust the Peak Voltagea. If the adaptive stickout window is not open, click on the button to open thewin

5. Adjust the Start Control Parameters (Optional)The start control parameters can be adjusted to define how the welding machine will respondwhen the a

6. Adjust the Shorting Control Parameters (Optional)The shorting control parameters can be adjusted to define how the welding machine will respondwhen

7. Adjust the End Condition Parameters (Optional)The end condition parameters can be adjusted to define how the welding machine will respond atthe end

8. “Go Figure” / Make the Waveform SynergicWeld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic,the waveform p

A.5 PRIMARY PULSE WAVEFORM COMPONENTSThe following paragraphs describe how peak current, peak time, frequency, and backgroundcurrent effect weld d

A.5.2 FREQUENCYFrequency, Figure A-7, is the number of pulses per second or, in theory, the number of welddroplets per second. Since increasing the f

A.6 SECONDARY WAVEFORM PARAMETERSA.6.1 RAMP-UP RATEThe ramp-up rate is the speed of current climb from the background current level to the peakcurren

A.7 APPLICATION EXERCISEThis application exercise steps the user through the development of a basic PowerWave weldingprogram using Wave Designer. Yo

JAVA RUNTIME ENVIRONMENT, VERSION 1.1.6, BINARY CODE LICENSEThis binary code license ("License") contains rights and restrictions associated

Our Experiment: We found multiple droplet detachment with an arc length that was too longat these waveform settings. To attain the proper droplet deta

7. Click on the button to display theWorkPoint Editor window. Check only thosewire feed speed points that have beendeveloped (only 150

A-20 Appendix APULSE WAVE SHAPING PRINCIPLESWAVE DESIGNER8. For a second workpointwe went to 300 in/min. Select the 300 in/min. wire feed speedfrom t

Appendix A A-21PULSE WAVE SHAPING PRINCIPLESWAVE DESIGNER12. Open the “Edit” screen and select only those workpoints that have been developed (150 an

A-22 Appendix APULSE WAVE SHAPING PRINCIPLESWAVE DESIGNER

B.1 APPENDIX OVERVIEWThis appendix provides a series of discussions on STT wave shaping principles and thedevelopment of custom STT waveforms. The c

B-2 Appendix BSTT WAVE SHAPING PRINCIPLESWAVE DESIGNERSTT Waveform EditorWire Feed SpeedPeak AmpsTailout SpeedPinch StartPinch | PeakPeak TimedV | dt

Appendix B B-3STT WAVE SHAPING PRINCIPLESWAVE DESIGNER27850060BACKGROUND AMPSPINCH AMPSPEAKAMPSTA ILOUTT1T2T3T5T6T7T0FIGURE B-2. WELD DROPLET TRANSF

B.3 STT (SURFACE TENSION TRANSFER)The Invertec STT power source is a high-frequency, current-controlled machine that deliverspower to the arc base

T2– T3The pinch mode applies an increasing, dual-slope ramp of current to theshorted electrode. The dual slope ramp of current accelerates the transfe

iv ivLICENSE INFORMATIONWAVE DESIGNER

B.4 STT WAVE DESIGN PROCESSThe Wave Designer software interfaces with the welding machine controller to permit real timecommunication of STT wave

B.4.1 SELECTING A STARTING WAVE SHAPEWhen customizing a waveform for a specific welding application, we recommend that you use awaveform in an existi

NOTE: You can edit one or more workpoints to values other than the defaults.However, the listing of wire feed speeds displayed must be the same orincr

2. Find the Optimal Arc CharacteristicsUse the following weld trials and adjustment sequence to tune the selected waveform for yourweld application at

3. Adjust the Start Control Parameters (Optional)The start control parameters can be adjusted to define how the welding machine will respondwhen the a

4. “Go Figure” / Make the Waveform SynergicWeld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic,the waveform p

B.5 PRIMARY STT WAVEFORM COMPONENTSThe following paragraphs describe how peak current, background current, and tailout effect welddroplet transfer

B.5.3 TAILOUTThe tailout provides additional heat without the molten droplet becoming too large. Increasetailout as needed to add heat to the arc wit

B.6 SECONDARY STT WAVEFORM COMPONENTSNOTE: The Invertec STT power source circuitry automatically establishes proper values for mostprimary and seco

STT WAVE SHAPING PRINCIPLESWAVE DESIGNERB.7 APPLICATION EXERCISEThis application exercise steps the user through the development of a basic PowerWav

1.1 PRODUCT OVERVIEWWave Designer is a visual, interactive software application used to modify wave shapes for usewith programmable waveform-controll

2.Pick a wire feed speedfrom the Wire FeedSpeed pulldown menu. We wanted to startwith a 130 in/min. WFS. But 130 is not aworkpoint in the selected wav

AAdaptive Loop ... A-4Adaptive Types ...

MMaking the Waveform Synergic ... A-13OOpen Circuit Voltage...

UUpgrade Firmware ... 2-5User Responsibility ...

INDEXIndex-4WAVEDESIGNER

In Windows NT 4.0 log on as AdministratorStart | Settings | Control Panel | System | Performance Virtual Memory Change... | Initial Size (MB): 100 | S

2.1 FILE STORAGE LOCATIONSThe Wave Designer default home directory is C:\Program Files\WaveDesigner. Subdirectories included with Wave Designer are a