Software

4.2.2.1 SP1 – Single

The Single software was developed during this project with the intent of controlling a single Lincoln Electric Power Wave F355i power supply (PS). This PS belongs to the robotic range of PSs from Lincoln Electric, and is normally controlled by the robot interface. In the absence of a robot the only available interfaces are provided by Ethernet and ArcLink . As was described in 4.2.1.2.1 ArcLink is an industry communication protocol. However, the Ethernet interface was preferred for this project as it is easier to integrate when developing a computer control system. This applies to all software packages developed in the scope of this work that use the Lincoln Electric PSs.

Before running the program, the required configuration files must be in the program directory.

These files are: “Single PowerWave.ini” and a “Mode XXX.scm” per PS per mode XXX defined in the “.ini” file, where XXX stands for the mode number. A default file is placed in the program directory when the software is installed. Information on these files can be found in Appendix A containing the program user manual.

Figure 4.15 – Screenshot of the Single software immediately after start-up.

When started, the program will initiate the communications with the Power Supply and will place them in ready state. While in ready state changes to the Work Point, Trim and Mode can be performed. The Work Point (WP) is the Wire Feed Speed (WFS) in inches per minute.

By setting the WFS all the other welding parameters are set according to the predefined synergic curve. To better understand the concept of trim and its operation the manufacturer’s manuals should be consulted [116]. In this application a representation of the range is displayed in terms of percentage, [-100%; 100%] Mode refers to a predefined set of rules which are defined to control the performance of the PS for the different stages of the welding process. It can be configured in the “Mode XXX.scm” file. These rules concern among other things the pre and post purge duration and the ability to jog the wire or purge gas. This file configuration is documented in section 3.2 of the software user manual (Appendix A).

In ready state it is possible to purge the gas and jog the wire in or out to prepare for the next weld. It is also possible to change the mode that is going to be used in the PS. Two other operations are possible: start welding and quit the program. To start welding the Start button needs to be pressed and the weld sequence will then be started. While welding, gas purge and wire jog functions are disabled as they cannot be performed during welding. When the Start button is pressed it is replaced by a Stop button that when pressed will halt the weld.

When the Quit Program button is pressed the PS is shutdown. This implies that the communications are disconnected and the user interface terminated.

This software has two ways of setting the values in the numerical input objects (controls). One that is most intuitive is by sliding the knob objects with the use of the mouse. The other is by double clicking in the control to generate an on-screen numerical keyboard. This allows for a more precise value entry in case the user is having difficulties updating the value with the mouse movement. A description of the program features and functions can be found in Appendix A containing the program user manual.

4.2.2.2 SP2 – Duo

As was explained in section 4.2.1.2.1 the Lincoln Electric PSs have no user interface and one had to be developed in order to operate them. Duo software was developed in the course of this project to control a set of two PSs. Unlike the Single software, the Duo is capable of handling two PSs at the same time. The operation can either be in Dual or Tandem mode according to the process requirements. In the Dual mode there is no synchronism between the PSs and in the Tandem mode their waveforms are synchronized.

Before running the program three or more configuration files must be in the program directory.

These files are: “Dual PowerWave.ini” or “Sync PowerWave.ini” depending on the torch type (Dual and Tandem respectively). And a “Mode XXX.scm” file per PS per mode defined in the

“.ini” file used. Information on these files can be found in Appendix B containing the program user manual. In Appendix B a description of the program features and functions can be found.

The philosophy behind Duo is the same. For further information concerning it please refer to section 4.2.2.1.

Figure 4.16 – Screenshot of the Duo software right after start-up.

4.2.2.3 SP3 – Motion

Motion is a software package developed in this project in order to control the Serimax Satrumax 5 welding head. The Motion software was developed around the Saturmax 5 welding carrier to work on a band-on-pipe system (Figure 4.1). This welding carrier is supplied with its own motion controller and configuration software. Due to some feature restrictions and also to be able to be vendor independent it was decided to have a commercial motion controller controlling the welding head and other parts of the system. The selected motion controller is the Galil Motion Control DMC-2280. This equipment is described in section 4.2.1.3.4.

In the Motion software it is possible to find all the required controls to interface with the welding head. Some of the objects in the screen can be executed while the system is on stand-by and some other can be used either while welding or stand-by. A description of the program features and functions can be found in Appendix C.

Figure 4.17 – Screenshot of the Motion software at start-up waiting for the weld carrier to reach the home position.