Appendix A | PULSE WAVE SHAPING PRINCIPLES |
A.7 APPLICATION EXERCISE
This application exercise steps the user through the development of a basic PowerWave welding program 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 along with this example, use the following set up:
Machine: | PowerWave 455, PowerFeed 10, Magnum 400 gun and cable, miscellaneous other |
| parts to complete welding cell |
Wire: | 0.035 |
Gas: | 90% Argon 10% CO2 |
Computer: See Section 2 of this manual for minimum requirements and connection diagrams. Click on the Wave Designer icon to start the program.
For this example, we developed a program to run wire feed speeds between 150 in/min. and 300 in/min. The user may want to develop more workpoints for practice.
Before starting the waveshape development process, confirm that the consumables are working properly with the welder. We recommend using a standard waveshape such as mode 5 to confirm that the welding system performs under normal conditions before attempting to develop waveshapes.
1.Select a wave shape. (From the tool bar, select ‘File’, ‘Open Waveform’.) For this exercise, select the “pulse.swf” wave shape. This wave shape is automatically loaded when the Wave Designer program is first used. Generally, the user should choose a waveshape file that has the closest welding performance to the intended application.
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File | Tools Print | Help |
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Open Waveform | Ctrl+O | |
Save Waveform As ... | ||
Save Waveform | Ctrl+S | |
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2.Pick a wire feed speed from the Wire Feed Speed pulldown menu. We started with the 150 in/min. WFS. Also, be sure to set the PowerFeed’s wire feed speed to the same WFS as the selected workpoint and set the trim to 1.00. (In this exercise, the WFS is 150 in/min.)
File Tools Print Help
Pulse Waveform Editor
Wire Feed Speed |
| 50 |
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| 80 |
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Ramp Up Rate | 600 | 110 |
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150 |
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Ramp Overshoot % | 205 |
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300 |
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| 400 |
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Peak Amps | 280 | 600 |
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700 |
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WAVE DESIGNER
