Weld data acquisition

Abstract

A weld data acquisition system collects data from the weld controller according to user selected collection parameters. The weld data acquisition system is able to transmit the data at high frequency to a weld data software utility that provides a user interface.

1 . An apparatus for transmitting weld data obtained from a weld control system that controls voltage or current output by a welder during welding, wherein the welding is controlled according to a weld control algorithm based on observed voltage and current values, the apparatus comprising:
 a plurality of weld data channels that are operatively coupled to the weld control system to carry data corresponding to the observed voltage and current values and one or more algorithm component values created by the weld control algorithm;   an input selector that selects a subset of the plurality of weld data channels for transmission;   a weld data sampler that samples data from the selected weld data channels and outputs the sampled data;   a data transmitter that transmits the sampled data.   
   
   
       2 . The apparatus of  claim 1  wherein the input selector comprises a user interface through which a user selects the subset of the plurality of weld data channels. 
   
   
       3 . The apparatus of  claim 2  wherein the user interface comprises a data channel configuration interface that is configured to accept and communicate one or more data sampling parameters to the weld data sampler and wherein the weld data sampler samples the data from the selected weld data channels according to the data sampling parameters. 
   
   
       4 . The apparatus of  claim 3  wherein the data channel configuration interface is configured to accept and communicate a preferred sampling rate to the weld data sampler. 
   
   
       5 . The apparatus of  claim 3  wherein the data channel configuration interface is configured to accept and communicate a preferred weld data resolution. 
   
   
       6 . The apparatus of  claim 3  wherein the data channel configuration interface is configured to present to the user an available bandwidth for transmission of data. 
   
   
       7 . The apparatus of  claim 3  wherein the data channel configuration interface is configured to accept and communicate a data collection trigger comprising a threshold value for data from at least one of the selected weld data channels and wherein the weld data sampler is prompted by occurrence of the data collection trigger to output sampled data. 
   
   
       8 . The apparatus of  claim 1  comprising a weld data channel database in communication with the input selector, the weld data channel database storing an identifier associated with each weld channel available for sampling by the weld data sampler and wherein the input selector selects weld data channels that have identifiers stored in the database. 
   
   
       9 . The apparatus of  claim 1  comprising a weld data buffer that receives weld data from the weld data sampler and accumulates the weld data for transfer to the weld data transmitter. 
   
   
       10 . The apparatus of  claim 1  comprising a weld data optimizer that receives data from the weld data sampler and configures the data for transmission by the transmitter. 
   
   
       11 . The apparatus of  claim 10  wherein the weld data optimizer organizes the weld data from the weld data sampler such that a minimal number of bits is required to represent the weld data. 
   
   
       12 . The apparatus of  claim 2  wherein the user interface comprises a set of computer-executable instructions stored on one or more computer-readable media. 
   
   
       13 . The apparatus of  claim 1  wherein the weld data transmitter is an Ethernet streaming output engine. 
   
   
       14 . The apparatus of  claim 1  wherein the algorithm component values comprise target levels for welding parameters. 
   
   
       15 . The apparatus of  claim 1  further comprising one or more peripheral data sources external to the weld controller that are accessible for selection by the input selector. 
   
   
       16 . A method that samples and transmits data from a weld control system that controls voltage or current output by a welder during welding, wherein the welding is controlled according to a weld control algorithm based on observed voltage and current values, the method comprising:
 providing a list of weld data channels that carry weld data values, wherein the weld data values include observed voltage and current values and control algorithm component values;   receiving a set of one or more selected weld data channels;   receiving configuration information associated with each of the selected weld data values, wherein the configuration information corresponds to one or more preferred sampling parameters;   sampling the selected weld data values at a first sample rate;   filtering the sampled weld data values according to the configuration information; and   transmitting the sampled data values.   
   
   
       17 . The method of  claim 16  further comprising organizing the sampled data values into a data structure that minimizes a number of bits required to represent the data. 
   
   
       18 . The method of  claim 16  wherein the configuration information includes a preferred sampling rate that is lower than the first sampling rate. 
   
   
       19 . The method of  claim 16  wherein the first sampling rate corresponds to a welding control frequency that corresponds to the frequency with which the weld controller samples the observed current and voltage values. 
   
   
       20 . The method of  claim 16  comprising periodically accumulating and transmitting the filtered weld data values. 
   
   
       21 . The method of  claim 16  comprising providing a graphic user interface for presenting available weld data channels and receiving selected weld data channels and configuration information. 
   
   
       22 . The method of  claim 16  wherein the step of transmitting the filtered weld data is performed by streaming the filtered weld data with an Ethernet streaming output engine. 
   
   
       23 . The method of  claim 16  including the step of monitoring for the occurrence of one or more trigger conditions corresponding to threshold values for one or more of the selected weld data values and wherein the step of transmitting the filtered weld data is performed in response to the occurrence of the one or more trigger conditions. 
   
   
       24 . The method of  claim 16  wherein the step of providing a list of weld data channels includes providing peripheral channels associated with peripheral data sources. 
   
   
       25 . Computer-readable media having computer-executable instructions stored thereon for performing method steps to sample and transmitting data from a weld control system that controls voltage or current output by a welder during welding, wherein the welding is controlled according to a weld control algorithm based on observed voltage and current values, the steps comprising:
 providing a list of weld data channels that carry weld data values, wherein the weld data values include observed voltage and current values and control algorithm component values;   receiving a set of one or more selected weld data channels having weld data values to be sampled and transmitted;   receiving configuration information associated with each of the selected weld data values, wherein the configuration information corresponds to one or more preferred sampling parameters;   sampling the selected weld data values at a first sample rate;   filtering the selected weld data values according to the configuration information; and   outputting the sampled data values for transmission.   
   
   
       26 . A method for acquiring data from a weld control system that controls voltage or current output by a welder during welding, wherein the welding is controlled according to a weld control algorithm based on observed voltage and current values, the method comprising:
 receiving a set of available weld data types;   providing a user interface for presenting the set of available weld data types available for sampling, wherein the weld data types include observed voltage and current values and control algorithm component values;   providing a user interface for receiving a set of selected weld data types and configuration information corresponding to preferred sampling parameters for each selected weld data type;   receiving weld data from the weld control system; and   decoding the received weld data according to the selected weld data types and configuration information; and   presenting the received weld data.   
   
   
       27 . The method of  claim 26  wherein the step of providing a user interface includes providing a user interface for accepting a preferred sampling rate. 
   
   
       28 . The method of  claim 26  wherein the step of providing a user interface includes providing a user interface for accepting one or more triggering conditions that signal the weld control system to commence data collection. 
   
   
       29 . Computer-readable media having computer-executable instructions stored thereon for performing method steps for acquiring data from a weld control system that controls voltage or current output by a welder during welding, wherein the welding is controlled according to a weld control algorithm based on observed voltage and current values, the method steps comprising:
 receiving a set of available weld data types;   providing a user interface for presenting the set of available weld data types available for sampling, wherein the weld data values include observed voltage and current values and control algorithm component values;   providing a user interface for receiving a set of selected weld data types and configuration information corresponding to preferred sampling parameters for each selected weld data type;   receiving weld data from the weld control system; and   decoding the received weld data according to the selected weld data types and configuration information; and   presenting the received weld data.   
   
   
       30 . The computer readable media of  claim 29  wherein the step of providing a user interface includes providing a user interface for accepting a preferred sampling rate. 
   
   
       31 . The computer readable media of  claim 29  wherein the step of providing a user interface includes providing a user interface for accepting one or more triggering conditions that signal the weld control system to commence data collection. 
   
   
       32 . An apparatus for transmitting weld data obtained from a weld control system that controls voltage or current output by a welder during welding, wherein the welding is controlled according to a weld control algorithm based on observed voltage and current values, the apparatus comprising:
 a plurality of means for carrying weld data corresponding to the observed voltage and current values and one or more algorithm component values created by the weld control algorithm;   means for selecting a subset of the plurality of means for carrying weld data for transmission;   means for sampling data from the selected weld data channels and outputting the sampled data;   means for transmitting the sampled data.   
   
   
       33 . The apparatus of  claim 32  means for accepting and communicating one or more data sampling parameters to the means for sampling and wherein the means for sampling samples the data from the selected means for carrying weld data according to the data sampling parameters. 
   
   
       34 . The apparatus of  claim 32  comprising means for receiving weld data from the means for sampling and accumulating the weld data for transfer to the means for transmitting the sampled data. 
   
   
       35 . The apparatus of  claim 32  comprising a means for optimizing weld data that receives data from the means for sampling and configures the data for transmission by the means for transmitting the sampled data.