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Section 3
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 welding
process; all other variables of the process are adjusted by the power source based on the single
controlling variable. This single controlling variable is known as a workpoint. For example, in
synergic pulse welding (GMAW-P), the operator can adjust the wire feed speed (WFS). The
WFS is the workpoint. The synergic power source will then set all other GMAW-P variables
based on the WFS by "looking up" the other variables from a pre-programmed weld table. See
Figure 3-1.
Wave Designer is a program that lets you develop a customized weld procedure by letting you
program each variable for multiple workpoints into a weld "look up" table.
Power Wave power sources go even a step further than simply "looking up" pre-programmed
variables from a weld table. If a selected WFS is between two pre-programmed workpoints, the
Power Wave will interpolate values for each of the welding variables. The result is a precise and
continuous range of welding control.
Refering to Figure 3-1, lets examine how this interpolation works by looking at one welding
variable — background amps. The operator selects a wire feed speed of 175 in/min. This value is
between the pre-programmed workpoints of 150 and 200 in/min. The Power Wave interpolates
between the pre-programmed background amp values of 80 and 60 and adjusts the background
amps to 70.
PRE-PROGRAMMED WELDING PROCESS VARIABLES
WORK-
POINTS
(WFS)
80
280
100
280
150
280
200
280
250
280
SOFTWARE OPERATION
FIGURE 3-1. WFS ENCODER AND WELD DATA TABLE.
WFS/AMPS
ENCODER
1.2
20
1.2
40
1.2
60
1.2
80
1.2
100
WAVE DESIGNER
NOTE: WFS ENCODER SETTING
DETERMINES WELDING
PROCESS VARIABLES PER
RELATED WELD TABLE.
PARAMETER VALUE
100
90
80
70
60
50
50
60
40
30
80
20
90
10
100
0
0
INTERPOLATED
INTERPOLATED
BACKGROUND AMPS
50
100
150
WIRE FEED SPEEDS
27850005
3-1
200
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