U.S. patent application number 10/663473 was filed with the patent office on 2005-03-17 for welding state detecting and transmitting device for resistance-welding machine.
This patent application is currently assigned to NADEX Co., Ltd. Invention is credited to Niwa, Kazuhiko.
Application Number | 20050056621 10/663473 |
Document ID | / |
Family ID | 34274385 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050056621 |
Kind Code |
A1 |
Niwa, Kazuhiko |
March 17, 2005 |
WELDING STATE DETECTING AND TRANSMITTING DEVICE FOR
RESISTANCE-WELDING MACHINE
Abstract
The welding state detecting and transmitting device 40 is
provided with a secondary battery 60 for accumulating power to be
supplied to components within the device 40, a charging circuit 58
that utilizes a portion of the welding current to charge the
secondary battery 60. A toroidal coil 42 is used for charging the
secondary battery 60 with welding current. The troidal coil 42 is
attached to secondary side conductor 32 and connected with the
charging circuit 58. The device 40 wirelessly transmits data
relating to the welding current detected by the toroidal coil 46.
The device 40 substantially reduces the burden of maintenance of
the device 40 required in prior art such as replacing a primary
battery or recharging a rechargeable battery periodically.
Inventors: |
Niwa, Kazuhiko;
(Nishikasugai-gun, JP) |
Correspondence
Address: |
ORRICK, HERRINGTON & SUTCLIFFE, LLP
4 PARK PLAZA
SUITE 1600
IRVINE
CA
92614-2558
US
|
Assignee: |
NADEX Co., Ltd
|
Family ID: |
34274385 |
Appl. No.: |
10/663473 |
Filed: |
September 15, 2003 |
Current U.S.
Class: |
219/109 |
Current CPC
Class: |
B23K 11/257
20130101 |
Class at
Publication: |
219/109 |
International
Class: |
B23K 011/24 |
Claims
1. A welding state detecting and transmitting device to be attached
to a secondary side of a resistance-welding machine, the device
comprising: an electricity storage means for accumulating electric
power to be supplied to components within the device; a charging
means for charging the electricity storage means by utilizing a
portion of welding current supplied through the secondary side of
the resistance-welding machine; a sensor for detecting indices
relating to welding state; and a transmitting means for wirelessly
transmitting data based on the indices detected by the sensor to an
external device.
2. A device as set forth in claim 1, wherein electricity storage
means, the charging means, the sensor, and the transmitting means
are formed in a unified manner.
3. A device as set forth in claim 1, wherein the charging means has
a coil provided around a conductor for supplying welding current,
the coil being utilized to charge the electricity storage
means.
4. A device as set forth in claim 1, wherein voltage between a pair
of conductors for supplying welding current is utilized for
charging the electricity storage means.
5. (Canceled)
6. (Canceled)
7. (Canceled)
8. (Canceled)
9. (Canceled)
10. (Canceled)
11. (Canceled)
12. (Canceled)
13. A welding state detecting and transmitting device to be
attached to a secondary side of a resistance-welding machine, the
device comprising: a sensor for detecting indices relating to
welding state; a transmitting means for wirelessly transmitting
data based on the indices detected by the sensor; a controlling
means for controlling detection of welding state indices in
accordance with detecting conditions stored within a memory; a
receiving means for receiving data wirelessly transmitted from an
external device; and a rewriting means for rewriting detecting
conditions stored within the memory with a newly received data by
the receiving means.
14. A welding state detecting and transmitting device to be
attached to a secondary side of a resistance-welding machine, the
device comprising: a sensor for detecting indices relating to
welding state; a transmitting means for wirelessly transmitting
data based on the indices detected by the sensor; a controlling
means for controlling transmission of the detected welding state
indices in accordance with transmitting conditions stored within a
memory; a receiving means for receiving data wirelessly transmitted
from an external device; and a rewriting means for rewriting
transmitting conditions stored within the memory with a newly
received data by the receiving means.
15. A welding state detecting and transmitting device to be
attached to a secondary side of a resistance-welding machine, the
device comprising: a sensor for detecting indices relating to
welding state; a transmitting means for wirelessly transmitting
data based on the indices detected by the sensor; a controlling
means for controlling the welding state detecting and transmitting
device in accordance with an operating program stored within a
memory; a receiving means for receiving an operating program
wirelessly transmitted from an external device; and a rewriting
means for rewriting the operating program stored within the memory
with a newly received operating program by the receiving means.
16. A welding state detecting system comprising the welding state
detecting and transmitting device as set forth in claims 13, 14 or
15, further comprising an external device for receiving a
transmitted data, wherein the external device comprises: a
receiving means for receiving the data wirelessly transmitted from
the welding state detecting and transmitting device; and a
processing means for processing the received data and generating
and outputting the processed data.
17. A welding state detecting and transmitting device to be
attached to a secondary side of a resistance-welding machine, the
device comprising: a sensor for detecting indices relating to
welding state; a memory for storing data based on the indices
detected by the sensor; a receiving means for receiving a data
request signal wirelessly transmitted from an external device; a
means for extracting the data from the memory in accordance with
the received data request signal; and a means for wirelessly
transmitting the extracted data to the external device.
18. A welding state detecting system comprising the welding state
detecting and transmitting device as set forth in claim 17 and an
external device for receiving a transmitted data, wherein the
external device comprises: a means for wirelessly transmitting the
data request signal to the welding state detecting and transmitting
device; a receiving means for receiving the data wirelessly
transmitted from the welding state detecting and transmitting
device; and a processing means for processing the received data and
generating and outputting the processed data.
19. A system as set forth in claim 18, wherein the external device
further comprises a control means for controlling the
resistance-welding machine in accordance with the received
data.
20. A welding state detecting device to be attached to a secondary
side of a resistance-welding machine, the device comprising: an
electricity storage means for accumulating electric power to be
supplied to components within the device; a charging means for
charging the electricity storage means by utilizing a portion of
welding current supplied through the secondary side of the
resistance-welding machine; and a sensor for detecting indices
relating to welding state.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a device for detecting
welding state indices such as welding current, welding pressure,
welding time (including indices relating thereto), etc. of a
resistance-welding machine, and for wirelessly transmitting data to
an external device based on the detected indices.
BACKGROUND OF THE INVENTION
[0002] A welding state detecting and recording device is known to
the art. The known device is provided with a toroidal coil for
detecting indices relating to welding current of a
resistance-welding machine, and a data storing means for storing
data based on the indices detected by the toroidal coil. The
toroidal coil and the data storing means are connected by a long
cable (first prior art).
[0003] Further, Japanese Laid Open Patent Publication (TOKKAIHEI)
8-99181 discloses a welding state detecting and transmitting
device. The device is utilized after being attached to a secondary
side of a resistance-welding machine. The welding state detecting
and transmitting device is provided with a toroidal coil for
detecting welding current indices of the resistance-welding
machine, and a transmitting means for wirelessly transmitting data
based on the indices detected by the toroidal coil to an external
device for processing received data (second prior art).
[0004] In the case of the first prior art, the toroidal coil must
be attached to a welding gun (a secondary side) of the
resistance-welding machine. The welding gun is moved in accordance
with a welding point within a work to be welded. Attaching the
toroidal coil, being connected to the cable, to the movable welding
gun often causes a problem that, as the welding gun is moved around
the work, the long cable connected to the toroidal coil is to catch
on or become entangled with the work or the other members. This
causes the cable to be severed, or damaging the work or the other
members. Further, it is even more likely that the cable will catch
on or become entangled with the work when the welding gun is caused
to move sequentially around the work so as to weld a plurality of
points. Therefore, it is difficult to adopt the first prior art in
an industrial application.
[0005] The device of the second prior art wirelessly transmits the
data to the external device, thereby resolving the problem in the
first prior art that may be caused by the long cable between the
toroidal coil and the data recording means.
DISCLOSURE OF THE INVENTION
[0006] In the second prior art, each component of the welding state
detecting and transmitting device, including a wireless
transmitting means, must be supplied with electric driving power.
If the welding state detecting and transmitting device of the
second prior art is connected to a commercial power source or the
like means by an electrical cable for obtaining electric driving
power from the commercial power source or the like means, the
advantages of the second prior art for wirelessly transmitting data
to the external device are lost. Consequently, a replaceable
primary battery or a rechargeable secondary battery must be
prepared within the welding state detecting and transmitting device
for obtaining the electric driving power. If the primary battery is
used within the device of the second prior art, the primary battery
must be replaced every time it is exhausted. If the rechargeable
secondary battery is used, the secondary battery must be connected
to the commercial power source or the like means for recharging the
battery every time it is exhausted.
[0007] The secondary side (welding gun) of the resistance-welding
machine is normally located at a tip portion of a welding robot or
an interior of a welding jig or the like. Consequently, physically
accessing to the welding state detecting and transmitting device
attached to the secondary side is troublesome. Replacing batteries
or recharging batteries within the device is also troublesome.
[0008] Further, in the second prior art, in a case where the
conditions for detecting welding state indices should be changed,
in a case where the conditions for transmitting the detected data
to the external device should be changed, or in a case where a
program for operating the welding state detecting and transmitting
device is to be rewritten, the welding state detecting and
transmitting device must be accessed physically by an operator.
[0009] Accessing physically by the operator to the welding state
detecting and transmitting device attached to the secondary side of
the resistance-welding machine is troublesome. Therefore,
maintenance operations, such as changing detecting conditions,
changing transmitting conditions, or rewriting operating program
constitute a considerable burden.
[0010] Thus maintenance operations of the second prior art are
considerable burden, and it is desirable to substantially reduce
this burden.
[0011] Further, in the second prior art, the data transmitted from
the welding state detecting and transmitting device may not be
received by the external device. Wireless transmitting and
receiving technique is often influenced by circumstances and
failure of data transmission cannot be perfectly prevented. The
second prior art lacks reliability.
[0012] The first object of the present invention is to
substantially reduce the burden of maintenance operations of the
welding state detecting and transmitting device, such as replacing
the primary battery, recharging the secondary battery, changing
detecting conditions, changing transmitting conditions, or
rewriting operating program, etc. of the welding state detecting
and transmitting device.
[0013] The second object of the present invention is to allow
necessary data to easily be obtained from the welding state
detecting and transmitting device even in cases where the external
device fails to receive the transmitted data from the welding state
detecting and transmitting device.
[0014] The present invention aims to solve at least a one of the
above two objects.
[0015] The present invention creates a new welding state detecting
and transmitting device. The welding state detecting and
transmitting device of the present invention is utilized after
being attached to a secondary side of a resistance-welding machine.
The device of the present invention is provided with an electricity
storage means for accumulating electric power to be supplied to
components within the device, and a charging means for charging the
electricity storage means, the charging means utilizing a portion
of welding current supplied through the secondary side of the
resistance-welding machine. The device of the present invention is
further provided with a sensor for detecting welding state indices,
and a transmitting means for wirelessly transmitting data based on
the detected indices to an external device.
[0016] Some examples of `wireless transmission` are the radio
method, whereby the data is transmitted via radio waves, and the
infrared ray method, whereby the data is transmitted utilizing
infrared rays, etc.
[0017] The present invention effectively solves the problem of the
prior art (the need to perform maintenance operations such as
replacing the primary battery or connecting the secondary battery
to a commercial power source or the like means and recharging it
every time the driving power is exhausted, etc.) by efficiently
utilizing characteristics inherent to the resistance-welding
machine.
[0018] The present invention also realizes a new welding state
detecting system. The new welding state detecting system is
provided with the welding state detecting and transmitting device
of the present invention, and an external device. The external
device has a wireless receiving means for receiving data that has
been wirelessly transmitted, and a processing means for processing
the received data. The processing means generates and outputs the
processed data.
[0019] According to the system, the external device and the welding
state detecting and transmitting device communicate wirelessly, so
the external device can be moved without a concern that a
connecting cable will be severed or will damage or destroy a work
or the other components. In addition, the external device outputs
useful data for monitoring the resistance-welding machine, or for
effectively controlling the resistance-welding machine.
[0020] Further, the present invention creates a new welding state
detecting and controlling system. The new detecting and controlling
system may be provided with the welding state detecting and
transmitting device and a controlling device of a
resistance-welding machine. The controlling device has a receiving
means for receiving data that has been wirelessly transmitted, and
a control means for controlling the progress of welding state of
the resistance-welding machine based on the data received by the
receiving means.
[0021] According to this system, the progress of the welding state
by the resistance-welding machine can be feedback controlled based
on data from the welding state detecting and transmitting device.
As a result, accurate resistance-welding operation can be
achieved.
[0022] The present invention also creates a new welding state
detecting system. The new detecting system may be provided with the
welding state detecting and transmitting device, and a welding
state monitoring device. The welding state monitoring device has a
receiving means for receiving data that has been wirelessly
transmitted, and a displaying means for displaying the welding
state of the resistance-welding machine based on the data received
by the receiving means.
[0023] According to this system, the welding state of the
resistance-welding machine can be monitored easily.
[0024] The welding state detecting and transmitting device of the
present invention may be provided with a sensor for detecting
welding state indices, a controlling means for controlling
detection by the sensor in accordance with detecting conditions, a
transmitting means for wirelessly transmitting data based on the
indices detected by the sensor, and a receiving means for receiving
data wirelessly transmitted from an external device. The detecting
conditions used by the controlling means are capable of being
rewritten to a newly received data describing a new detecting
conditions. The new data describing the new detecting conditions is
transmitted wirelessly from the external device and received by the
receiving means.
[0025] The present device eliminates the necessity of troublesome
maintenance operations, such as physically accessing to the device
attached to the secondary side of the resistance-welding machine,
removing the device from the secondary side and rewriting detecting
conditions, etc. Consequently, the burden of maintenance operations
can be substantially reduced.
[0026] A welding state detecting and transmitting device of the
present invention may be provided with a storing means for storing
programs for operating the welding state detecting and transmitting
device, and a receiving means for receiving operating programs
wirelessly transmitted from an external device. The operating
programs stored in the storing means are capable of being rewritten
with a new operating program transmitted wirelessly from the
external device and received by the receiving means.
[0027] The present device eliminates the necessity of troublesome
maintenance operations, such as physically accessing to the device
attached to the secondary side of the resistance-welding machine,
removing the device from the secondary side and rewriting the
operating programs. Consequently, the burden of maintenance of the
operating programs for the device can be substantially reduced.
[0028] A welding state detecting and transmitting device of the
present invention may be provided with a receiving means for
receiving a data demanding signal wirelessly transmitted from the
external device, a controlling means capable of controlling the
extraction of the requested data from a data storing means, and a
transmitting means for wirelessly transmitting the extracted data
to the external device.
[0029] According to the present device, in cases where the external
device fails to receive the necessary data from the welding state
detecting and transmitting device, the failed data can be
recollected from the welding state detecting and transmitting
device.
[0030] The term `means` in the present specification is not
restricted to hardware, but also includes combinations of hardware
and software. Further, one function of one means may be realized
through the use of two or more items of hardware or software, or
the two or more functions of the two or more means may be realized
through the use of one item of hardware or software. For example,
the transmitting means and the receiving means may be realized
through one item of hardware such as the transmitting and receiving
circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is an explanatory view showing a welding state
detecting and transmitting device and a welding state detecting
system of a first embodiment.
[0032] FIG. 2 is an explanatory view showing a welding state
detecting and transmitting device and a welding state detecting
system of a second embodiment.
PREFERRED EMBODIMENT OF THE INVENTION
[0033] (First Embodiment)
[0034] FIG. 1 is an explanatory view showing a welding state
detecting and transmitting device 40 of a first embodiment, and a
welding state detecting system 90. The system 90 is provided with a
resistance-welding machine 10, the welding state detecting and
transmitting device 40, and an external device 70 for receiving
data from the device 40, storing the received data, processing the
received data, storing the processed data, and outputting the
received and the processed data.
[0035] The resistance-welding machine 10 is provided with a circuit
unit 20 and a welding gun unit 30. The circuit unit 20 is provided
with a commutating circuit 23, an inverter circuit 24, and a
transformer 27, these being connected in sequence. The commutating
circuit 23 is connected with a commercial three-phase alternating
current source 22. The circuit unit 20 is further provided with a
driving circuit 25 connected with the inverter circuit 24, and a
welding state controlling device 26 connected with the driving
circuit 25. The welding state controlling device 26 has a CPU 26a,
a ROM 26b, a RAM 26c, and a monitor 26d, etc. The welding gun unit
30 is provided with a pair of secondary side conductors 32
connected with a secondary side of the transformer 27 of the
circuit unit 20, and a pair of welding electrodes 34, the welding
electrodes 34 being attached to the tips of the secondary side
conductors 32. The secondary side conductors 32 of the welding gun
unit 30 are capable of freely moving by means of an actuator (not
shown), in a direction of applying pressure on a work (to-be-welded
members W1 and W2).
[0036] The welding state detecting and transmitting device 40 is
provided with a circuit unit 50, a toroidal coil 46 for detecting
welding current, and a toroidal coil 42 for charging a rechargeable
battery 60 by using a portion of welding current. The circuit unit
50 and the toroidal coils 46 and 42 are unified by being connected
by cables 43 and 47, these having a short length such that they do
not impede the operation or movement of the welding gun unit 30.
One of the secondary side conductors 32 of the welding gun unit 30
is inserted through a hollow center hole of the circular toroidal
coil 46. The toroidal coil 46 generates voltage that is
proportional to changing rate of welding current. The same
secondary side conductor 32 of the welding gun unit 30 is inserted
through a hollow center hole of the circular toroidal coil 42. The
toroidal coil 42 generates voltage due to welding current.
[0037] The circuit unit 50 is provided with a gain circuit 52, an
integrated circuit 54, an A/D conversion circuit 56, a CPU 64, and
a data transmitting and receiving circuit 68, these being connected
in sequence. A RAM 62 and a ROM 66 are also connected with the CPU
64. By utilizing, for example, a widely used short-range wireless
communication module (a Bluetooth module or the like), the data
transmitting and receiving circuit 68 may be manufactured easily at
low cost.
[0038] The circuit unit 50 is further provided with a charging
circuit 58 and a secondary battery (a rechargeable battery, for
example a lithium ion battery) 60 that is connected with the
charging circuit 58. The charging circuit 58 is connected with the
toroidal coil 42 for obtaining charging voltage from the welding
current. The toroidal coil 42 is attached to the welding gun unit
30 in the same way as the toroidal coil 46. The toroidal coils 42
and 46 can also constitute one shared toroidal coil. Electric
driving power is supplied from the secondary battery 60 to all
components of the welding state detecting and transmitting device
40. Moreover, the circuit unit 50 is also provided with a timer
(not shown) utilized for counting welding time, and a pressure
detecting means (not shown) utilized for detecting wielding
pressure between the electrodes 34, 34.
[0039] The charging circuit 58 is provided with a charging control
member 58a. The charging control member 58a performs various
controls concerning charging. Some examples are:
[0040] (1) The charging control member 58a controls the charging
current of the secondary battery 60 to be constant. In this manner,
excessive current or excessive voltage is prevented from being
applied to the secondary battery 60.
[0041] (2) When the quantity of electric power accumulated in the
secondary battery 60 reaches or exceeds a specified value, the
charging control member 58a halts the charging of the secondary
battery 60. Excessive charging power is not supplied to the
secondary battery 60.
[0042] (3) When the quantity of electric power accumulated in the
secondary battery 60 is at or below a specified value, the charging
control member 58a causes the secondary battery 60 to be charged
utilizing a portion of welding current. This aspect prevents
situations where the quantity of electric power accumulated in the
secondary battery 60 is insufficient and thereby halts the
operation of the device 40.
[0043] The CPU 64 controls the circuit unit 50 in accordance with
prescribed detecting conditions stored within the RAM 62. Examples
of detecting conditions include the detecting period (start time to
finish time) of the welding state indices, detecting intervals,
type of resistance-welding machine (AC welder, inverter welder);
detecting range (100 A.about.1000 A, 1000 A.about.10,000 A, 10,000
A.about.100,000 A), etc.
[0044] The CPU 64 also controls the data transmitting and receiving
circuit 68 in accordance with prescribed transmitting conditions
stored within the RAM 62. Examples of transmitting conditions
include the transmitting intervals, and transmitting power.
[0045] Operating programs for the device 40 are stored within the
RAM 62. A variety of programs with differing contents are stored.
Examples of the operating programs include a program for processing
the detected value by the toroidal coil 46 (calculating mean values
or effective values, etc.), a program for defining the operating
conditions of the data transmitting and receiving circuit 68, a
program for controlling the charging control member 58a of the
charging circuit 58, etc.
[0046] Further, the RAM 62 is capable of storing the previous
10,000 multipoint items of welding status indices (welding current,
mean welding current, mean welding voltage, pressures between the
pair of electrodes 34,24 and welding time at each previous welding
point). The welding status indices detected or processed from the
detected indices is stored within the RAM 62 each time welding is
performed. In the case where the stored welding data exceeds 10,000
multipoint items, the new welding data writes sequentially over the
oldest welding data.
[0047] The external device 70 for receiving welding status indices,
processing the received welding status indices, and outputting the
received or processed data is provided with a data transmitting and
receiving circuit 72, a CPU 74, and a data outputting circuit 80,
these being connected in sequence. A RAM 76 and a ROM 78 are also
connected with the CPU 74. Examples of a data outputting device 70
are mobile telephones, personal computers, or PDAs (Personal
Digital Assistants), etc. The portability of mobile telephones is
high, however, the processability and storage capacity thereof is
usually low, therefore, mobile telephones are suitable for
monitoring received welding data (welding current values, etc.).
Personal computers, and PDAs, etc. usually have a large
processability and storage capacity, therefore, personal computers,
and PDAs, etc. are suitable for graphic displaying the received
welding data, analyzing the received welding data, storing the
received welding data, and inputting the new detecting and
transmitting conditions based on the results of data analysis, etc.
Welding current data for a plurality of resistance-welding
machines, corresponding to several thousand multipoint items, can
easily be stored using a personal computer, and PDA, etc.
[0048] According to the system 90 of the first embodiment, the
welding data detected, processed or analyzed by the welding state
detecting and transmitting device 40 can be utilized simultaneously
by a plurality of data outputting devices 80 (mobile telephones,
personal computers, and PDAs, etc.).
[0049] The data transmitting and receiving circuit 72 preferably
utilizes, for example, a widely utilized short-range wireless
communication module (a Bluetooth module or the like). It is
expected that mobile telephones having short-range wireless
communication modules loaded therein will become widespread. The
transmitted data from the device 40 may be easily monitored by
bringing the mobile telephone to the vicinity of the device 40. The
mobile telephone may be used as the external device 70.
[0050] The operation of the welding state detecting system 90 of
the first embodiment will now be described. The commutating circuit
23 of the resistance-welding machine 10 rectifies the three-phase
alternating voltage from the commercial three-phase alternating
current source 22 and outputs direct voltage. The inverter circuit
24 contains a switching element. The inverter circuit 24 obeys
controlling pulses from the welding state controlling device 26,
conveyed via the driving circuit 25, to discontinuously perform
high-frequency switching, thereby converting the direct input
voltage from the commutating circuit 23 into a high-frequency
alternating pulse that is output therefrom. The alternating pulse
output from the inverter circuit 24 is supplied to a primary side
coil of the welding transformer 27. As a result, an alternating
pulse similar to that of the primary side coil is output to a
secondary side coil of the welding transformer 27. The current
generated by the secondary side coil of the transformer 27 is
increased so that large amount of joule heat is generated while the
welding current passes through the work W1 and W2.
[0051] The secondary side alternating pulses, that is, a welding
current 1, flows into the pair of welding electrodes 34 via the
pair of secondary side conductors 32. In this manner, the welding
current 1 that has flowed into the welding electrodes 34 is
supplied to the work W1 and W2 (to-be-welded members W1 and W2),
and the joule heat is created within the work W1 and W2 thereby
resistance-welding the work W1 and W2 by the joule heat.
[0052] The toroidal coil 46 detects the magnitude of the welding
current 1. The toroidal coil 46 is a part of the welding state
detecting and transmitting device 40. The toroidal coil 46 outputs
a signal corresponding to an amount of change of the welding
current 1 per a unit time. Since the signal indicates changing
rates of the welding current 1, the signal itself does not indicate
the magnitude of the welding current 1. Consequently, the signal,
indicating changing rates of the welding current 1, is first input
into the gain circuit 52 of the circuit unit 50 to be amplified,
then is input into the integrated circuit 54 and integrated, then
is output. The integrated value corresponds to the magnitude of the
welding current 1.
[0053] The signal outputted from the integrated circuit 54,
corresponding to the welding current 1 and suitable for processing
and analysis, is first input into the A/D conversion circuit 56 and
is converted into digital data. Then the converted digital data is
input into the CPU 64. The CPU 64 processes and analyzes the
received welding status indices and generates useful data such as
indices that will make the next resistance-welding to be performed
effectively. When necessary, the CPU 64 reads the data from the RAM
62 and the ROM 66 for processing and analyzing, and the processed
and analyzed data is stored within the RAM 62 and the ROM 66. The
data that has been detected, processed and analyzed by the CPU 64
is wirelessly transmitted from the data transmitting and receiving
circuit 68 to the external device 70 and the resistance-welding
machine 10. The resistance-welding machine 10 may be considered as
one of the external device.
[0054] Furthermore, the CPU 64 also controls the data transmitting
and receiving circuit 68. For example, the CPU 64 controls the
timing of transmitting data, and controls the data to be
transmitted, etc.
[0055] In the case where the wirelessly transmitted data is
received by the data transmitting and receiving circuit 72 of the
external device 70, the data is first input into the CPU 74. The
CPU 74 processes and analyzes the received data and generates
useful data such as indices that will make the next
resistance-welding to be performed effectively or that will help
understanding of the history of resistance-welding operations. When
necessary, the CPU 74 reads the data from the RAM 76 and the ROM 78
for processing and analyzing, and the processed and analyzed data
is stored within the RAM 76 and the ROM 78.
[0056] The processed and analyzed data by the CPU 74 is output
(displayed, printed, etc.) by the data outputting circuit 80.
[0057] Further, in the case where the data wirelessly transmitted
from the welding state detecting and transmitting device 40 is
received by the welding state controlling device 26 of the
resistance-welding machine 10, the wirelessly transmitted data is
output to the monitor 26d. This monitor display 26d allows the
welding states indices from the device 40 to be seen easily.
Moreover, after the wirelessly transmitted data has been received,
the CPU 26a outputs control signals to the driving circuit 25 on
the basis of the wirelessly transmitted data. By performing this
type of feedback adjustment based on the wirelessly transmitted
data, accurate resistance-welding can be achieved by the
resistance-welding machine 10. Further, the wirelessly transmitted
data that has been received may be stored in the ROM 26b or RAM
26c.
[0058] The device 40 and the device 70 are provided with the data
transmitting and receiving circuits 68 and 72 respectively. That
is, the device 40 has a data receiving function in addition to a
data transmitting function, and the device 70 has a data
transmitting function in addition to a data receiving function.
[0059] The device 70 is capable of transmitting, to the data
transmitting and receiving circuit 68 of the welding state
detecting and transmitting device 40, data which describes welding
state indices detecting conditions (the conditions according to
which welding state indices will be detected) and data transmitting
conditions (the conditions according to which data will transmitted
from the device 40). When the data describing welding state indices
detecting conditions and data transmitting conditions is
transmitted to the device 40, the CPU 64 stores the data within the
RAM 62. Thereafter, the CPU 64 detects welding state indices in
accordance with the newly defined detecting conditions, and
transmits the detected welding state indices in accordance with the
newly defined transmitting conditions.
[0060] Further, the device 70 is capable of transmitting operating
programs, defining how the device 40 should perform operations, to
the data transmitting and receiving circuit 68 of the device 40.
After the operation program has been transmitted, the CPU 64
rewrites the operation program stored in the RAM 62. After the new
operation program has been rewritten in the RAM 62, the new
operation program is executed.
[0061] Further, the external device 70 is capable of transmitting a
data request signal to the device 40. When the data request signal
has been transmitted to the device 40, the CPU 64 extracts the
requested data from the RAM 62 and the ROM 66. Then, the CPU 64
controls the transmission of the extracted data from the data
transmitting and receiving circuit 68. By using the data request
signal, previous welding data that has been failed to receive by
the external device 70 may be resent so that the external device 70
is capable to store all necessary data.
[0062] (Second Embodiment)
[0063] FIG. 2 is an explanatory view showing a welding state
detecting and transmitting device 40 and a welding state detecting
system 90 of a second embodiment.
[0064] In this system, a pair of cables 44 is connected with a
charging circuit 58 of the device 40. Each of the pair of cables 44
is connected with one of the pair of secondary side conductors 32.
Further, the pair of cables 44 bifurcates and is connected with an
A/D conversion circuit 61. The A/D conversion circuit 61 is
connected with a CPU 64. By this means, voltage data originating
from the pair of secondary side conductors 32, 32 can be detected,
processed, and analyzed, etc. These points are the main differences
of the second embodiment from the first embodiment.
[0065] In addition to the functions described above, the welding
state detecting and transmitting device 40 of the first or second
embodiments also has the following effects.
[0066] (1) By using the charging toroidal coil 42 (first
embodiment) or cables 44 (second embodiment) and the charging
circuit 58, a portion of the welding current automatically charge
the secondary battery 60. Frequent battery changing operations or
frequent battery recharging operations are not necessary any more.
As a result, maintenance operations are extremely easy
(substantially maintenance-free).
[0067] (2) In the case where a plurality of the welding state
detecting and transmitting device of the second prior art is
attached to a plurality of individual resistance-welding machines,
maintenance operations must be performed on each of the plurality
of individual resistance-welding machines, i.e. rewriting detecting
and transmitting conditions, and rewriting operation programs,
etc., and this is extremely troublesome. In contrast, in the
welding state detecting and transmitting device 40 of the first or
second embodiments, detecting and transmitting conditions and the
operation programs can be rewritten wirelessly from the device 70.
The maintenance operations are not time-consuming.
[0068] (3) In the case the external device 70 failed to receive the
transmitted data from the device 40, the failed data may be resent
from the device 40 again by using the data request signal. The
external device 70 is capable to store all necessary data.
[0069] Specific examples of embodiments of the present invention
are presented above, but these merely illustrate some possibilities
of the invention and do not restrict the claims thereof. The art
set forth in the claims includes variations, transformations and
modifications to the specific examples set forth above.
[0070] Furthermore, the technical elements disclosed in the present
specifications or figures may be utilized separately or in all
types of conjunctions and are not limited to the conjunctions set
forth in the claims at the time of submission of the
application.
[0071] Furthermore, the art disclosed in the present specification
or figures may be utilized to simultaneously realize a plurality of
aims or to realize one of these aims.
* * * * *