Electrode diameter sensing consumables

Abstract

Electrode diameter sensing consumables are disclosed. An example shielded metal arc welding (SMAW) torch comprises: a handle; a clamp coupled to the handle configured to open and close to hold a SMAW electrode, the clamp comprising a pivot configured to rotate based on a degree of openness of the clamp; and a potentiometer coupled to the pivot such that an output of the potentiometer is representative of a degree of rotation of the pivot

1 . A shielded metal arc welding (SMAW) electrode holder, comprising:
 a handle;   a clamp coupled to the handle configured to open and close to hold a SMAW electrode, the clamp comprising a pivot configured to rotate based on a degree of openness of the clamp; and   a potentiometer coupled to the pivot such that an output of the potentiometer is representative of a degree of rotation of the pivot.   
     
     
         2 . The SMAW electrode holder of  claim 1 , further comprising a spring configured to exert a force to provide a closing tendency to the clamp. 
     
     
         3 . The SMAW electrode holder of  claim 1 , wherein the potentiometer is configured to, when a first signal is applied to the potentiometer, output a second signal representative of a size of an electrode held by the clamp. 
     
     
         4 . A welding system, comprising:
 a material sensing and control system configured to receive an output from a potentiometer of a shielded metal arc welding (SMAW) electrode holder and to determine an electrode size based on the output; and   a controller configured to:
 determine, based on the electrode size, at least one of an arc starting parameter or a welding parameter; and 
 control the welding system to implement the determined arc starting parameter or the welding parameter. 
   
     
     
         5 . The welding system of  claim 4 , wherein the material sensing and control system is configured to receive the output from the potentiometer continuously. 
     
     
         6 . The welding system of  claim 4 , wherein the material sensing and control system is configured to receive the output from the potentiometer once per material change. 
     
     
         7 . The welding system of  claim 4 , wherein the output comprises a voltage. 
     
     
         8 . The welding system of  claim 4 , wherein the material sensing and control system is configured to translate the output by matching the output to a predetermined sensor signal. 
     
     
         9 . The welding system of  claim 4 , wherein the material sensing and control system is configured to translate the output by determining a predetermined output range into which the output falls. 
     
     
         10 . A method, comprising:
 receiving an output from a potentiometer of a shielded metal arc welding (SMAW) electrode holder;   determining an electrode size based on the output;   determining, based on the electrode size, at least one of an arc starting parameter or a welding parameter; and   controlling the welding system to implement the determined arc starting parameter or the welding parameter.   
     
     
         11 . The method of  claim 10 , wherein the receiving of the output comprises receiving the output from the potentiometer continuously. 
     
     
         12 . The method of  claim 10 , wherein the material sensing and control system is configured to receive the output from the potentiometer once per material change. 
     
     
         13 . The method of  claim 10 , wherein receiving the output comprises receiving a voltage signal. 
     
     
         14 . The method of  claim 10 , wherein the determining the electrode size comprises translating the output by matching the output to a predetermined sensor signal. 
     
     
         15 . The method of  claim 10 , wherein the determining the electrode size comprises translating the output by determining a predetermined output range into which the output falls.