An adaptive welding system including a plurality of welding machines, an edge computing system configured to gather weld data from a first welding machine from the plurality of welding machines, and a weld analytics system configured to build an optimized operational model for the first welding machine based at least upon the weld data. The weld analytics system is further configured to transmit the optimized operational model to the first welding machine as a firmware image.

The invention described herein generally pertains to a system and method for collecting one or more welding parameters in real time during creation of one or more welds using a welding sequence. The one or more welding parameters can be associated with a particular welding sequence. Moreover, based on the one or more welding parameters collected, a modeled welding parameter can be generated to increase quality, efficiency, and the like. A collection component collects real time welding parameter data from which a quality manager component creates a modeled welding parameter. The modeled welding parameter can be employed for the welding sequence to monitor or track the welding parameter during a subsequent weld.

In one embodiment, a modeling process adds unique numbers for field welds or flange bolt-up connections to a virtual construction model of an infrastructure construction project. Based on the virtual construction model and a fabrication data file that describes a portion of the infrastructure construction project, a QC drawing generation process generates a QC drawing for the portion of the infrastructure construction project that includes balloons linked to locations of field welds or flange bolt-up connections, each balloon including the unique number of a corresponding field weld or flange bolt-up connection. A copy of the QC drawing is provided to a field inspection worker. Subsequently, a marked-up copy of the QC drawing is received back that includes field inspection results associated with the unique number of each field weld or flange bolt-up connection. The marked-up copy may be maintained in a document control system.

A weld analytics system and method of tracking weld quality for a group of sequential welds. In one example, a weld analytics system receives a welding plan for a plurality of welds being performed by at least one welding machine. The weld analytics system determines an overall weld quality for the plurality of welds, based at least upon weld data from the at least one welding machine; and transmits a signal indicative of the overall weld quality of the plurality of welds to an interactive user terminal.

A method inspects weld quality in-situ. The method obtains a plurality of sequenced images of an in-progress welding process and generates a multi-dimensional data input based on the plurality of sequenced images and/or one or more weld process control parameters. The parameters may include: (i) shield gas flow rate, temperature, and pressure; (ii) voltage, amperage, wire feed rate and temperature (if applicable); (iii) part preheat/inter-pass temperature; and (iv) part and weld torch relative velocity). The method generates defect probability and analytics information by applying one or more computer vision techniques on the multi-dimensional data input. The analytics information includes predictive insights on quality features of the in-progress welding process. The method then generates a 3-D visualization of one or more as-welded regions, based on the analytics information, and the plurality of sequenced images. The 3-D visualization displays the quality features for virtual inspection and/or for determining weld quality.

A welding control system is provided for monitoring welding operations of a plurality of welding units within a production facility configured to provide weld data associated with the respective mechanical entities, including a determination unit configured to determine for each type of mechanical entity a corresponding welding error rate on the basis of weld data received from welding units of the production facility, a calculation unit configured to calculate for each type of mechanical entity the number of faulty mechanical entities of the respective entity type depending on the number of mechanical entities used and configured to weight the calculated number of faulty mechanical entities of the respective entity type with a predetermined manufacturing effort value.

A welding-type system includes a welding-type power supply to output welding-type power, and a controller connected to the welding-type power supply. The controller is configured to set a value of a control variable of a control loop of the welding-type power supply, the control loop controlling the welding-type power. The controller is also configured to adjust the value of the control variable while monitoring the control loop. In response to detecting oscillation in the control loop, the controller is configured to determine a weld circuit inductance associated with a weld circuit of the welding-type system based on a relationship between the adjusted control variable value and the weld circuit inductance.

The invention described herein generally pertains to a system and method for collecting one or more welding parameters in real time during creation of one or more welds using a welding sequence. The one or more welding parameters can be associated with a particular welding sequence. Moreover, based on the one or more welding parameters collected, a modeled welding parameter can be generated to increase quality, efficiency, and the like. A collection component collects real time welding parameter data from which a quality manager component creates a modeled welding parameter. The modeled welding parameter can be employed for the welding sequence to monitor or track the welding parameter during a subsequent weld.

A main controller may be used to provide integrated, centralized, and optimized handling of telematics data in welding arrangements. The main controller may receive from other components of a welding arrangement, telematics data, and may apply at least some processing to the telematics data, to enable use of the telematics data by a remote entity. The telematics data may comprises data relating to an engine used in driving one or more components of the welding arrangement, data relating to one or more components of the welding arrangement, and/or data relating to welding operations performed via the welding arrangement. The processing of telematics data may comprise formatting data in accordance with a single standard format, digitizing analog data, and/or processing data for communication to the remote entity. The main controller may provide telematics client and/or host node functions, such as based on the controller area network (CANBus) protocol.

Systems and methods for welding, and more specifically to a controller with the capability to power and control a welder and an associated workpiece heater. Exemplary systems and methods may further control a welder and associated heater according to feedback from the welder and/or heater.