System for measuring energy using digitally controlled welding power sources

Abstract

A method and system for internally determining, within a welding power supply, the energy input into a weld during a welding operation. The method includes determining a total energy input into the weld during a first time period, and determining a length of the weld made during the first time period.

What is claimed is: 
     
         1 - 52 . (canceled) 
     
     
         53 . A method for monitoring a welding operation within a welding power supply, comprising:
 sampling pairs of instantaneous voltage and current values from a welding waveform during a first time period;   determining instantaneous energy values from the sampled pairs of instantaneous voltage and current values;   summing the instantaneous energy values to determine a total energy input into a weld during the first time period; and   comparing the determined total energy input to an acceptable range of total energy values for the welding operation or the determined instantaneous energy values to an acceptable range of instantaneous energy values for the welding operation.   
     
     
         54 . The method of  claim 53 , further comprising transmitting at least one of said instantaneous energy values and said determined total energy input over a network connection to an electronic device. 
     
     
         55 . The method of  claim 54 , wherein said network connection includes a wireless connection. 
     
     
         56 . The method of  claim 54 , wherein said network connection includes a wired connection. 
     
     
         57 . The method of  claim 54 , wherein said electronic device is one of a laptop, a PDA or a smart-phone. 
     
     
         58 . The method of  claim 54 , wherein said network connection is configured to allow central review of the welding operation. 
     
     
         59 . The method of  claim 53 , further comprising issuing an alert when the total energy is outside of the acceptable range of total energy values or the determined instantaneous energy value is outside of the acceptable range of instantaneous energy values. 
     
     
         60 . A welding power supply configured to monitor a welding operation, comprising:
 a sampler configured to sample pairs of instantaneous voltage and current values from a welding waveform during a first time period;   a first determiner configured to determine instantaneous energy values from the sampled pairs of instantaneous voltage and current values;   a summer configured to sum the instantaneous energy values;   a second determiner configured to determine a total energy input into a weld during the first time period; and   a comparer configured to compare the determined total energy input to an acceptable range of total energy values for the welding operation or the determined instantaneous energy values to an acceptable range of instantaneous energy values for the welding operation.   
     
     
         61 . The welding power supply of  claim 60 , further comprising:
 a transmitter operably connected to a network connection and configured to transmit at least one of said instantaneous energy values and said determined total energy input over said network connection to an electronic device.   
     
     
         62 . The welding power supply of  claim 61 , wherein said network connection includes a wireless connection. 
     
     
         63 . The welding power supply of  claim 61 , wherein said network connection includes a wired connection. 
     
     
         64 . The welding power supply of  claim 61 , wherein said electronic device is one of a laptop, a PDA or a smart-phone. 
     
     
         65 . The welding power supply of  claim 61 , wherein said network connection is configured to allow central review of the welding operation. 
     
     
         66 . The welding power supply of  claim 60 , further comprising an alerter configured to issue an alert when the total energy is outside of the acceptable range of total energy values or the determined instantaneous energy value is outside of the acceptable range of instantaneous energy values. 
     
     
         67 . A method for monitoring a welding operation within a welding power supply, comprising:
 sampling pairs of instantaneous voltage and current values from a welding waveform during a first time period;   determining instantaneous energy values from the sampled pairs of instantaneous voltage and current values;   summing the instantaneous energy values to determine a total energy input into a weld during the first time period;   determining a length of the weld made during the first time period;   determining an energy input per unit length during the first time period using the determined total energy input and the determined length of the weld; and   comparing the determined energy input per unit length to an acceptable range of energy input per unit length values for the welding operation.   
     
     
         68 . The method of  claim 67 , further comprising transmitting at least one of said instantaneous energy values, said determined total energy input, said determined length of the weld, and said determined energy input per unit length over a network connection to an electronic device. 
     
     
         69 . The method of  claim 68 , wherein said network connection includes a wireless connection. 
     
     
         70 . The method of  claim 68 , wherein said network connection includes a wired connection. 
     
     
         71 . The method of  claim 68 , wherein said electronic device is one of a laptop, a PDA or a smart-phone. 
     
     
         72 . The method of  claim 68 , wherein said network connection is configured to allow central review of the welding operation. 
     
     
         73 . The method of  claim 67 , further comprising issuing an alert when the total energy is outside of the acceptable range of total energy values, the determined instantaneous energy value is outside of the acceptable range of instantaneous energy values, or the determined energy input per unit length value is outside of the acceptable range of energy input per unit length values. 
     
     
         74 . A welding power supply configured to monitor a welding operation, comprising:
 a sampler configured to sample pairs of instantaneous voltage and current values from a welding waveform during a first time period;   a first determiner configured to determine instantaneous energy values from the sampled pairs of instantaneous voltage and current values;   a summer configured to sum the instantaneous energy values;   a second determiner configured to determine a total energy input into a weld during the first time period;   a third determiner configured to determine a length of the weld made during the first time period;   a fourth determiner configured to determine an energy input per unit length during the first time period using the determined total energy input and the determined length of the weld; and   a comparer configured to compare the determined energy input per unit length to an acceptable range of energy input per unit length values for the welding operation.   
     
     
         75 . The welding power supply of  claim 74 , further comprising:
 a transmitter operably connected to a network connection and configured to transmit at least one of said instantaneous energy values, said determined total energy input, said determined length of the weld, and said determined energy input per unit length over said network connection to an electronic device.   
     
     
         76 . The welding power supply of  claim 75 , wherein said network connection includes a wireless connection. 
     
     
         77 . The welding power supply of  claim 75 , wherein said network connection includes a wired connection. 
     
     
         78 . The welding power supply of  claim 75 , wherein said electronic device is one of a laptop, a PDA or a smart-phone. 
     
     
         79 . The welding power supply of  claim 75 , wherein said network connection is configured to allow central review of the welding operation. 
     
     
         80 . The welding power supply of  claim 74 , further comprising an alerter configured to issue an alert when the total energy is outside of the acceptable range of total energy values, the determined instantaneous energy value is outside of the acceptable range of instantaneous energy values, or the determined energy input per unit length value is outside of the acceptable range of energy input per unit length values.