Intelligent waveform selection for a welding system having particular electrical output characteristics

Abstract

Systems and methods for selecting a welding output waveform based on characterizing a welding circuit output path with respect to its electrical characteristics. At least one electrical characteristic (e.g., inductance, resistance) of a welding output circuit path connected to a welding power source is determined. A welding output waveform is selected from a plurality of welding output waveforms based on the determined electrical characteristics. As a result, the selected welding output waveform is matched to the welding output circuit path electrical characteristics to provide superior welding performance.

What is claimed is: 
     
         1 - 21 . (canceled) 
     
     
         22 . A welding system, comprising:
 a welding power supply having a welding output;   a welding output circuit path coupled to said welding output; and   a welding output analyzer circuit coupled to said welding power supply, where said welding output analyzer circuit commands said welding power supply to output a regulated signal to said welding output circuit path;   wherein said welding output analyzer circuit uses said regulated signal to determine a first parameter of said welding output circuit path, which is at least one of a resistance and an inductance of said welding output circuit path;   wherein said welding output analyzer circuit selects a welding output voltage for a welding operation based on said determined first parameter; and   wherein said welding power supply automatically uses said selected welding output voltage for said welding operation performed following said selection of said welding output voltage.   
     
     
         23 . The welding system of  claim 22 , wherein said regulated signal is a regulated voltage signal. 
     
     
         24 . The welding system of  claim 22 , wherein said regulated signal is a regulated current signal. 
     
     
         25 . The welding system of  claim 22 , wherein said welding output analyzer determines a second parameter of said welding output circuit path, which is the other of said inductance or said resistance, and said selected welding output voltage is selected based on each of said first and second parameters. 
     
     
         26 . The welding system of  claim 22 , wherein said welding output analyzer uses a look-up table to select said welding output voltage. 
     
     
         27 . The welding system of  claim 22 , further comprising a display which displays an indication to a user, where said indication is based on said determined first parameter. 
     
     
         28 . The welding system of  claim 22 , further comprising a welding tool coupled to said welding output circuit path for said determination of said first parameter. 
     
     
         29 . The welding system of  claim 22 , wherein said welding output analyzer circuit selects a welding output current for said welding operation based on said determined first parameter; and wherein said welding power supply automatically uses said selected welding output current for said welding operation performed following said selection of said welding output current. 
     
     
         30 . The welding system of  claim 22 , wherein said selected welding output voltage is one of a plurality of predetermined welding output voltages. 
     
     
         31 . The welding system of  claim 27 , where said indication identifies an incompatibility between said determined first parameter and a selected welding operation. 
     
     
         32 . The welding system of  claim 22 , wherein said welding output path includes one or more of a welding cable, a welding tool, and a workpiece to be welded. 
     
     
         33 . The welding system of  claim 22 , wherein said welding output analyzer circuit uses said regulated signal to automatically determine said first parameter for a subsequent welding operation after completion of said welding operation, and where said first parameter for said subsequent welding operation is used to select a second welding output voltage for said subsequent welding operation, where said second welding output voltage is different than said welding output voltage. 
     
     
         34 . A method of welding, comprising:
 providing a welding power supply having a welding output;   coupling a welding output circuit path to said welding output;   outputting, using a welding output analyzer circuit, a regulated signal to said welding output circuit path from said welding output;   determining, with said welding output analyzer circuit, a first parameter of said welding output circuit path, where said first parameter is one of a resistance and an inductance of said welding output circuit path;   selecting, using said welding output analyzer circuit, a welding output voltage for a welding operation based on said determined first parameter; and   automatically using said selected welding output voltage for said welding operation performed following said selection of said welding output voltage.   
     
     
         35 . The welding method of  claim 34 , wherein said regulated signal is a regulated voltage signal. 
     
     
         36 . The welding method of  claim 34 , wherein said regulated signal is a regulated current signal. 
     
     
         37 . The welding method of  claim 34 , further comprising determining, with said welding output analyzer, a second parameter of said welding output circuit path, which is the other of said inductance or said resistance of said welding output circuit path, and selecting said welding output voltage based on each of said first and second parameters. 
     
     
         38 . The welding method of  claim 34 , wherein said welding output analyzer uses a look-up table to select said welding output voltage. 
     
     
         39 . The welding method of  claim 34 , further comprising displaying an indication to a user, where said indication is based on said determined first parameter. 
     
     
         40 . The welding method of  claim 34 , further comprising coupling a welding tool to said welding output circuit path for said determination of said first parameter. 
     
     
         41 . The welding method of  claim 34 , further comprising selecting a welding output current for said welding operation based on said determined first parameter; and automatically using said selected welding output current for said welding operation performed following said selection of said welding output current. 
     
     
         42 . The welding method of  claim 34 , wherein said selected welding output voltage is one of a plurality of predetermined welding output voltages. 
     
     
         43 . The welding method of  claim 39 , where said indication identifies an incompatibility between said determined first parameter and a selected welding operation. 
     
     
         44 . The welding method of  claim 34 , wherein said welding output path includes one or more of a welding cable, a welding tool, and a workpiece to be welded. 
     
     
         45 . The welding method of  claim 34 , further comprising using said regulated signal to automatically determine said first parameter for a subsequent welding operation after completion of said welding operation, and using said first parameter for said subsequent welding operation to select a second welding output voltage for said subsequent welding operation, where said second welding output voltage is different than said welding output voltage. 
     
     
         46 . A welding system, comprising:
 a welding power supply having a welding output;   a welding output circuit path coupled to said welding output; and   a welding output analyzer circuit coupled to said welding power supply, where said welding output analyzer circuit commands said welding power supply to output each of a regulated voltage signal and a regulated current signal to said welding output circuit path;   wherein said welding output analyzer circuit uses said regulated voltage and current signals to determine a first parameter of said welding output circuit path, which is at least one of a resistance and an inductance of said welding output circuit path;   wherein said welding output analyzer circuit selects a welding output voltage for a welding operation based on said determined first parameter; and   wherein said welding power supply automatically uses said selected welding output voltage for said welding operation performed following said selection of said welding output voltage.