Page 3 - WAVE DESIGNER; TABLE OF CONTENTS; Page
WAVE DESIGNER i TABLE OF CONTENTS Page License Information ..................................................................................................... ii Introduction .................................................................................................... Section 1 1.1 Product ...
Page 4 - ii; LICENSE INFORMATION
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 not agree to all of the terms of this agreement, click the button that indicatesyou do not accept the terms and do not install the software. (If applic...
Page 5 - iii
JAVA RUNTIME ENVIRONMENT, VERSION 1.1.6, BINARY CODE LICENSE This binary code license ("License") contains rights and restrictions associated with use of the accompanying Java Runtime Environmentsoftware and documentation ("Software"). Read the License carefully before using the Soft...
Page 7 - Section 1; INTRODUCTION; COMPUTER SYSTEM REQUIREMENTS
1.1 PRODUCT OVERVIEW Wave Designer is a visual, interactive software application used to modify wave shapes for use with programmable waveform-controlled welding machines such as the Power Wave 455. The Wave Designer software package includes a standard set of waveforms commonly used in commercial a...
Page 9 - Section 2; SOFTWARE INSTALLATION
2.1 FILE STORAGE LOCATIONS The Wave Designer default home directory is C:\Program Files\WaveDesigner. Subdirectories included with Wave Designer are as follows: • arcScope - user data file for ArcScope traces ( Wave Designer Pro option only) • bin - system executables and support files, do not tampe...
Page 10 - Lincoln Electric Wave Designer Version 1.0; Welcome to Wave Designer; EQUIPMENT INTERFACE CONNECTIONS; Wave Designer
FIGURE 2-1. WAVE DESIGNER STARTUP SCREEN. 2-2 Section 2 SOFTWARE INSTALLATION WAVE DESIGNER Lincoln Electric Wave Designer Version 1.0 Copyright © 1998 The Lincoln Electric Company All Rights Reserved United States Patent Pending Comments? Write to [email protected] Initializing ... P...
Page 11 - How to enable the external serial port on your ThinkPad
Section 2 2-3 SOFTWARE INSTALLATION WAVE DESIGNER SW1 SW2 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 ON ON CONTROL BOX CONTROL BOARD 27850003 FRONT PANEL POWER SOURCE RS232 CABLE COMPUTER SYSTEM 27850004 FIGURE 2-2. CONTROL BOARD DIP SWITCH SETTING. FIGURE2-3. INTERFACE CONNECTION. PLEASE NOTE: Some IBM ThinkP...
Page 12 - Status; UPGRADE FIRMWARE
2.4 EQUIPMENT/SOFTWARE STARTUP When the Wave Designer software installation is complete, Wave Designer is listed among the programs you can start up from the Windows startup screen. Click on START, point to theprograms option, then click on the Wave Designer option. The Wave Designer Welcome screen ...
Page 13 - SYNERGIC WELDING AND WORKPOINTS; Prior to using; Section 3; SOFTWARE OPERATION; WFS; ENCODER; PRE-PROGRAMMED WELDING PROCESS VARIABLES; WIRE FEED SPEEDS
3.1 SYNERGIC WELDING AND WORKPOINTS Prior to using Wave Designer it is important to have a good understanding of the concepts of synergic welding and workpoints. Synergic welding is basically “one knob control” of a weldingprocess; all other variables of the process are adjusted by the power source ...
Page 14 - SOFTWARE OPERATION; Tool Bar; The workpoint selector includes a pulldown window for; Variable Parameters; The listing of variable parameters display the active parameter; Graphic Editor; The graphic editor displays the active wave shape. The wave shape
3.2 WORKING IN WAVE DESIGNER 3.2.1 WAVEFORM EDITOR WINDOW Refer to the Waveform Editor window in Figure 3-2 and the related usage instructions. FIGURE 3-2. WAVEFORM EDITOR WINDOW. 3-2 Section 3 SOFTWARE OPERATION WAVE DESIGNER Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms...
Page 15 - The optional window buttons open additional windows used during; Wave Designer Status Bar; This status bar provides a scrolled listing of recent program; About the Procedure
Section 3 3-3 SOFTWARE OPERATION WAVE DESIGNER 5. Optional Windows The optional window buttons open additional windows used during wave shaping. Optional windows in the pulse Waveform Editor include Start, Adapt, Short,End, and About. Details about the use of most optional windows is covered in the ...
Page 16 - File
3-4 Section 3 SOFTWARE OPERATION WAVE DESIGNER 3.2.2 WAVEFORM EDITOR TOOL BAR There are four menu selections available on the pulse waveform editor tool bar. The followingdescribes how to use the File, Tools, and Print menus. The Help menu is self explanatory. 3.2.2.1 FILE MENU The File menu provide...
Page 17 - Tools
3.2.2.2 TOOLS MENU The Tools menu includes waveform displayoptions and other tools required to operate Wave Designer . The Tools menu options include the following: Pulse Editor Ctrl+P Display the Pulse Waveform Editor screen. STT Editor Ctrl+E Display the STT Waveform Editor screen. Simplify Editor...
Page 18 - Wave Designer Pro Waveform Editor; Wave Designer ArcScope; Volt
3.2.2.3 PRINT MENU Print menu options enable you to print out a waveform display, ArcScope screen, or tabularwaveform data listing as shown below. The Print menu options include the following: 3-6 Section 3 SOFTWARE OPERATION WAVE DESIGNER Wave Designer Pro Waveform Editor Printed on Thu Jul 09 07:2...
Page 19 - WorkPoint Editor
3.2.3 EDITING AND SELECTING WORKPOINTS For each custom welding application, unique wave shapes are developed for specific workpointswithin the range of workpoints defined for the application. In Wave Designer the range of workpoints and the specific workpoint values are defined in a Workpoint Editor...
Page 20 - WORKPOINT; FIXED VALUE
3.2.3.1 EDITING WORKPOINTS Clicking on the Edit button in the waveform Editor window opens a Workpoint Editor window. TheWorkpoint Editor window displays a listing of workpoints for the selected standard waveform. Usethe Workpoint Editor window according to the following descriptions and guidelines:...
Page 22 - to move the hot spot. Press Ctrl and an; NODES; CAUTION
3.2.4 EDITING VARIABLE PARAMETERS The following is a summary of the different methods available for changing (editing) parametervalues on the Waveform Editor screen and other display screens accessible through Wave Designer . Read the following information carefully before making parameter changes o...
Page 23 - WAVE DESIGN PROCESS; REFERENCE
Section 3 3-11 SOFTWARE OPERATION WAVE DESIGNER 3.3 WAVE DESIGN PROCESS The wave design process is a series of operations that allows you to quickly modify a standardwaveform to fit your specific welding application. The following process flowchart applies to apulse waveform, but is similar to the p...
Page 24 - DOWNLOADING WAVE SHAPES
3-12 Section 3 SOFTWARE OPERATION WAVE DESIGNER 3.4 DOWNLOADING WAVE SHAPES The Power Wave stores wave shapes in the welding machine controller memory. The memorystructure does not allow an upload or download of individual wave shapes. When downloadingwave shapes to the welding machine, the entire w...
Page 25 - following descriptions.
Section 3 3-13 SOFTWARE OPERATION WAVE DESIGNER 2. Select a blank Mode or a defined Mode for overwrite by clicking on a box to the left of the Modes listing. When the Mode is selected, a checkmark appears in the Mode box. 3. Enter the file name of the desired waveform in the box to the right of the ...
Page 27 - Wave Designer Pro; Section 4; ARCSCOPE
4.1 INTRODUCTION The following describes the ArcScope application included with Wave Designer Pro . The ArcScope application provides oscilloscope type displays of power source output waveforms onyour computer monitor. 4.1.1 USING THE ARC SCOPE WINDOW Refer to the ArcScope window in Figure 4-1 and t...
Page 28 - Status Bar; Graphical Display Area; Scope Configuration
6. Status Bar The status bar provides a scrolled listing of recent Wave Designer program operations, error conditions, etc., and three operational status indicators. The adaptiveindicator is also a button that toggles between the Adaptive and Non-Adaptive mode. 7. Graphical Display Area The graphica...
Page 31 - TROUBLESHOOTING PROCEDURE; Section 5; TROUBLESHOOTING
5.1 OVERVIEW Wave Designer troubleshooting is limited to the software application. If the welding machine does not respond, recheck the interface connection and communication setup requirements insection 2 of this manual. Refer to the welding machine service manuals for troubleshootingsuspected equi...
Page 33 - A.1 APPENDIX OVERVIEW; Contents Description; Appendix A; PULSE WAVE SHAPING PRINCIPLES
A.1 APPENDIX OVERVIEW This appendix provides a series of discussions on pulse wave shaping principles and thedevelopment of custom GMAW pulse waveforms. The contents of this appendix are arranged asfollows: Paragraph No./Title Contents Description A.2 GMAW Pulse Overview How the pulse waveform trans...
Page 34 - A.2 GMAW PULSE OVERVIEW; Primary Pulse Waveform Components; and; Secondary Pulse Waveform Components
A-2 Appendix A PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp Overshoot % 26.4 33.4 21 40 .100 3.0 1.2 250 -20 600 Edit Start About Adapt Short End ...
Page 35 - Ramp-up current forms the weld droplet at the tip of the electrode.
Appendix A A-3 PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER • From time T1 to T2: Background current maintains an arc, and a weld bead starts toform. • From time T2 to T3: Ramp-up current forms the weld droplet at the tip of the electrode. • From time T3 to T4: Peak current and peak time separate the...
Page 36 - ADAPTIVE
A.3 ADAPTIVE AND NON-ADAPTIVE MODE To proficiently develop welding procedures using Wave Designer , the key concept of Adaptive versus Non-Adaptive welding must be understood. Wave Designer allows the user to set the machine into either adaptive or non-adaptive mode. During the wave design process b...
Page 37 - A.4 PULSE WAVE DESIGN PROCESS; The
A.4 PULSE WAVE DESIGN PROCESS The Wave Designer software interfaces with the welding machine controller to permit real time communication of pulse wave design changes. Refer to paragraph 2.3 for equipment interfaceconnections. Use the following wave design process to customize a standard wave shape....
Page 38 - new file name to the waveform.
A.4.1 SELECTING A STARTING WAVE SHAPE When customizing a waveform for a specific welding application, we recommend that you use awaveform in an existing weld file. An existing weld file can be selected from the systemWeldFilesfolder in the Wave Designer directory as follows: a. Click on a standard w...
Page 40 - Open the Adaptive Loop / Find the Optimal Arc Characteristics; a. Click on the button to open the Adapting; Adapting Stickout
2. Open the Adaptive Loop / Find the Optimal Arc Characteristics Use the following weld trials and adjustment sequence to tune the selected waveform for yourweld application at the designated workpoint (wire feed speed). Weld trials and adjustments aremore easily performed with one person welding wh...
Page 41 - Close the Adaptive Loop / Adjust the Peak Voltage
3. Close the Adaptive Loop / Adjust the Peak Voltage a. If the adaptive stickout window is not open, click on the button to open the window. Select the adaptive option to close the adaptive loop. Verify that the adaptivebutton lights up. NOTE: When on-line with the adaptive loop closed, the wave sha...
Page 42 - Start Control
5. Adjust the Start Control Parameters (Optional) The start control parameters can be adjusted to define how the welding machine will respondwhen the arc is struck. To view the start control window, click on the button on the Waveform Editor screen.Adjust the start control parameters to accommodate ...
Page 43 - Shorting Control
6. Adjust the Shorting Control Parameters (Optional) The shorting control parameters can be adjusted to define how the welding machine will respondwhen the arc shorts to the weld puddle. To view the shorting control window, click on the button on the Waveform Editor screen.Adjust the shorting contro...
Page 44 - End Conditioning; END AMPS; Amp • Time: This parameter indicates the power of the ending pulse.
7. Adjust the End Condition Parameters (Optional) The end condition parameters can be adjusted to define how the welding machine will respond atthe end of a weld application. To view the end condition window, click on the button on the Waveform Editor screen.Adjust the end condition parameters to ac...
Page 45 - “Go Figure” / Make the Waveform Synergic; Developing the 2nd Workpoint; Develop the second workpoint in the same manner as the first.; Workpoints Interpolation
8. “Go Figure” / Make the Waveform Synergic Weld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic,the waveform parameters automatically adjust to programmed data table values. The data tablevalues are unique for selected wire feed speeds. Thereby, the output of...
Page 46 - A.5 PRIMARY PULSE WAVEFORM COMPONENTS
A.5 PRIMARY PULSE WAVEFORM COMPONENTS The following paragraphs describe how peak current, peak time, frequency, and backgroundcurrent effect weld droplet transfer. A.5.1 PEAK CURRENT AND PEAK TIME A combination of peak current and peak time, Figure A-6, applies a force to detach the welddroplet from...
Page 48 - A.6 SECONDARY WAVEFORM PARAMETERS
A.6 SECONDARY WAVEFORM PARAMETERS A.6.1 RAMP-UP RATE The ramp-up rate is the speed of current climb from the background current level to the peakcurrent level. Faster ramp-up rates tend to produce a plasma plume that quickly surrounds theend of the next droplet. A.6.2 RAMP OVERSHOOT % The ramp overs...
Page 49 - A.7 APPLICATION EXERCISE; Pick a wire feed speed
A.7 APPLICATION EXERCISE This application exercise steps the user through the development of a basic PowerWave weldingprogram using Wave Designer . Your application most likely will vary from this example but the concepts outlined are recommended for all development work. If you would like to follow...
Page 50 - Click on the button and select the; Using the adaptive stickout window or the green
Our Experiment: We found multiple droplet detachment with an arc length that was too longat these waveform settings. To attain the proper droplet detachment, we reduced the peakcurrent value to 250 amps and found improved weld droplet transfer. But reducing the peakcurrent also caused the arc to be ...
Page 52 - Open the adapting stickout window and select
A-20 Appendix A PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER 8. For a second workpoint we went to 300 in/min. Select the 300 in/min. wire feed speed from the pulldown menu in Waveform Editor window. Reset the PowerFeed for 300 in/min.with a 1.00 trim. 9. Open the adapting stickout window and select t...
Page 53 - Open the “Edit” screen and select only those
Appendix A A-21 PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER 12. Open the “Edit” screen and select only those workpoints that have been developed (150 and300 in/min.). Select the button tointerpolate the remaining workpoints. The function gives a estimation of the values needed for the other wire fee...
Page 55 - B.1 APPENDIX OVERVIEW; Appendix B; STT WAVE SHAPING PRINCIPLES
B.1 APPENDIX OVERVIEW This appendix provides a series of discussions on STT wave shaping principles and thedevelopment of custom STT waveforms. The contents of this appendix are arranged as follows: Paragraph No./Title Contents Description B.2 STT Overview How the STT waveform transfers weld droplet...
Page 56 - AMPERES; Primary STT Waveform Components; Secondary STT Waveform Components
B-2 Appendix B STT WAVE SHAPING PRINCIPLES WAVE DESIGNER STT Waveform Editor Wire Feed Speed Peak Amps Tailout Speed Pinch Start Pinch | Peak Peak Time dV | dt detect Backgrd Amps 14.00 1.0 .70 140 Edit Start About Explain Wave Designer Pro Off Line - stt.swf 500 400 300 200 100 0 0 1 2 3 4 5 6 7 8 ...
Page 57 - BACKGROUND AMPS
Appendix B B-3 STT WAVE SHAPING PRINCIPLES WAVE DESIGNER 27850060 BACKGROUND AMPS PI NCH AMPS PEAK AMPS TAILOUT T 1 T 2 T 3 T 5 T 6 T 7 T 0 FIGURE B-2. WELD DROPLET TRANSFER. • From time T 0 to T 1 : Background current is a steady-state current level, between 50 and (Background Current) 100 Amps tha...
Page 58 - Surface Tension TransferTM; Electrode; T T; Time; background current; between 50 and 100 Amps is delivered to the arc prior; Ball time
B.3 STT (SURFACE TENSION TRANSFER) The Invertec STT power source is a high-frequency, current-controlled machine that deliverspower to the arc based on immediate arc requirements. The Invertec STT produces largeelectrode current changes within microseconds. It operates in the short-circuiting weldin...
Page 59 - pinch mode; applies an increasing, dual-slope ramp of current to the; peak
T 2 – T 3 The pinch mode applies an increasing, dual-slope ramp of current to the shorted electrode. The dual slope ramp of current accelerates the transfer ofmolten metal by the electric pinch forces. The pinch force is directly proportionalto the square of the pinch current. T 3 – T 5 dV/dt is the...
Page 60 - B.4 STT WAVE DESIGN PROCESS
B.4 STT WAVE DESIGN PROCESS The Wave Designer software interfaces with the welding machine controller to permit real time communication of STT wave design changes. Refer to paragraph 2.3 for equipment interfaceconnections. Use the wave design process to customize a standard wave shape. The process i...
Page 62 - the arc control is OFF.
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 orincreasing from top to bottom. All four wire feed speeds must be assignedvalues, but multiple workpoints can share the same value. The reason you would ed...
Page 64 - STT Start Control
3. Adjust the Start Control Parameters (Optional) The start control parameters can be adjusted to define how the welding machine will respondwhen the arc is struck. To view the start control window, click on the button on the Waveform Editor screen.Adjust the start control parameters to accommodate ...
Page 65 - “Go Figure” / Make the Waveform Synergic
4. “Go Figure” / Make the Waveform Synergic Weld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic,the waveform parameters automatically adjust to programmed data table values. The data tablevalues are unique for selected wire feed speeds. Thereby, the output of...
Page 66 - B.5 PRIMARY STT WAVEFORM COMPONENTS; ADJUST ARC LENGTH WITH PEAK CURRENT; are required to reduce spatter.
B.5 PRIMARY STT WAVEFORM COMPONENTS The following paragraphs describe how peak current, background current, and tailout effect welddroplet transfer. B.5.1 PEAK CURRENT The peak current control acts similar to an “arc pinch” control. Peak current serves to establishthe arc length and promote good fus...
Page 67 - Applications using 100% CO
B.5.3 TAILOUT The tailout provides additional heat without the molten droplet becoming too large. Increasetailout as needed to add heat to the arc without increasing arc length. (This will allow for fastertravel speeds and improved wetting). As tailout is increased, the peal and/or background curren...
Page 68 - B.6 SECONDARY STT WAVEFORM COMPONENTS
B.6 SECONDARY STT WAVEFORM COMPONENTS NOTE: The Invertec STT power source circuitry automatically establishes proper values for mostprimary and secondary waveform components. The values can be adjusted, but shouldnot be set far from their automatically set values. B.6.1 PINCH START The pinch start i...
Page 69 - B.7 APPLICATION EXERCISE
STT WAVE SHAPING PRINCIPLES WAVE DESIGNER B.7 APPLICATION EXERCISE This application exercise steps the user through the development of a basic PowerWave/STTwelding program using Wave Designer . Your application most likely will vary from this example but the concepts outlined are recommended for all...
Page 70 - from the Wire Feed; adjust the STT variables to improve welding performance
2. Pick a wire feed speed from the Wire Feed Speed pulldown menu. We wanted to startwith a 130 in/min. WFS. But 130 is not aworkpoint in the selected wave shapeapplication. Use the Workpoint Editor windowto change the second workpoint (170 in/min.)to 130. 3. Select 130 from the Wire Feed Speed pulld...
Page 71 - INDEX; WAVEDESIGNER
A Adaptive Loop .......................................................................................................... A-4 Adaptive Types ........................................................................................................ A-9 Adaptive and Non-Adaptive Mode .....................
