U.S. patent application number 10/765587 was filed with the patent office on 2005-07-28 for engine welder with shielding gas generation.
This patent application is currently assigned to Lincoln Global, Inc., a Delaware corporation. Invention is credited to Stava, Elliott K..
Application Number | 20050161450 10/765587 |
Document ID | / |
Family ID | 34795507 |
Filed Date | 2005-07-28 |
United States Patent
Application |
20050161450 |
Kind Code |
A1 |
Stava, Elliott K. |
July 28, 2005 |
ENGINE WELDER WITH SHIELDING GAS GENERATION
Abstract
A liquid and gas separator to generate a shielding gas from the
exhaust gas of an internal combustion engine. The liquid and gas
separator can be a separate portable component or a component that
is integrated with the arc welder.
Inventors: |
Stava, Elliott K.; (Sagamore
Hills, OH) |
Correspondence
Address: |
FAY, SHARPE, FAGAN, MINNICH & MCKEE, LLP
1100 SUPERIOR AVENUE, SEVENTH FLOOR
CLEVELAND
OH
44114
US
|
Assignee: |
Lincoln Global, Inc., a Delaware
corporation
|
Family ID: |
34795507 |
Appl. No.: |
10/765587 |
Filed: |
January 27, 2004 |
Current U.S.
Class: |
219/133 ;
219/74 |
Current CPC
Class: |
B23K 9/324 20130101;
B23K 35/38 20130101; B23K 9/164 20130101 |
Class at
Publication: |
219/133 ;
219/074 |
International
Class: |
B23K 009/173 |
Claims
1. An integrated welder comprising: a. a housing that at least
partially contains an internal combustion engine and an electric
current generator, said electric current generator at least
partially connected to said internal combustion engine to be at
least partially driven thereby; and, b. a portable exhaust gas
separator at least partially connected to said internal combustion
engine to at least partially receive exhaust gas generated by said
internal combustion engine, said exhaust gas separator at least
partially separating a shielding gas from said exhaust gas to at
least partially be used as a shielding gas for an ongoing arc
welding procedure.
2. The welder as defined in claim 1, wherein said exhaust gas
separator is at least partially housed in said housing.
3. The welder as defined in claim 1, wherein said exhaust gas
separator is at least partially powered by the current generated by
said electric current generator.
4. The welder as defined in claim 3, including an electric circuit
that controls power to said exhaust gas separator.
5. The welder as defined in claim 1, wherein said exhaust gas
separator at least partially separates liquids from said exhaust
gas.
6. The welder as defined in claim 5, wherein said exhaust gas
separator includes a condenser.
7. The welder as defined in claim 1, wherein said exhaust gas
separator includes a gas filter.
8. The welder as defined in claim 1, wherein said shielding gas
includes a majority weight percent of carbon dioxide.
9. The welder as defined in claim 1, including a gas compressor to
at least partially compress said shielding gas from said exhaust
gas separator.
10. The welder as defined in claim 9, wherein said gas compressor
is at least partially powered by the current generated by said
electric current generator.
11. The welder as defined in claim 10, including an electric
circuit that controls power to said electric current generator.
12. The welder as defined in claim 9, including a gas cylinder
fluidly connected to said air compressor.
13. The welder as defined in claim 12, including a pressure monitor
to monitor a pressure in said gas cylinder to generate a control
signal to activate or deactivate said air compressor based at least
partially on a detected air pressure level in said gas
cylinder.
14. The welder as defined in claim 1, wherein said housing includes
wheels to enable said housing to be rolled over a ground
surface.
15. The welder as defined in claim 1, including a welding circuit
that is designed to provide sufficient voltage and current to a
workpiece to cause an electric arc to form between a consumable
electrode and said workpiece, said welding circuit at least
partially controlling at least one welding parameter between said
consumable electrode and said workpiece, said welding parameter
includes a parameter selected from the group consisting of voltage,
current, energy, power, polarity, current wave form or combinations
thereof.
16. The welder as defined in claim 15, wherein said consumable
electrode is a consumable flux cored metal electrode.
17. A portable exhaust gas separator designed to be connected to an
exhaust of a portable internal combustion engine to produce a
shielding gas for use in an ongoing welding operation comprising:
a. a liquid separating mechanism designed to remove a majority of
water and water vapor from an exhaust gas generated by the internal
combustion engine; and, b. a gas separating mechanism to separate a
majority of an arc welding shielding gas from the exhaust gas, said
arc welding shielding gas including a gas selected from the group
consisting of carbon dioxide, carbon monoxide or combinations
thereof.
18. The exhaust gas separator as defined in claim 17, wherein said
portable exhaust gas separator is releasably connectable to the
internal combustion engine.
19. The exhaust gas separator as defined in claim 17, wherein said
liquid separating mechanism includes a condenser, a dehumidifier,
coalescing filter, particulate filter or combinations thereof.
20. The exhaust gas separator as defined in claim 17, wherein said
gas separating mechanism includes a gas filter, a scrubber, a gas
absorber, a gas adsorber or combinations thereof.
21. The exhaust gas separator as defined in claim 17, including a
gas compressor to at least partially compress said shielding
gas.
22. A method of generating a shielding gas for use in an ongoing
arc welding process from an exhaust gas of an internal combustion
engine comprising: a. providing an exhaust gas from a portable
internal combustion engine; b. providing a portable gas and liquid
separator; c. removing at least a majority of water and water vapor
from said exhaust gas by said portable gas and liquid separator;
and, d. separating at least a majority of said shielding gas from
said exhaust gas by said portable gas and liquid separator, said
shielding gas including a gas selected from the group consisting of
carbon dioxide, carbon monoxide or mixtures thereof.
23. The method as defined in claim 22, including the step of
compressing said shielding gas.
24. The method as defined in claim 22, wherein said portable
internal combustion engine and said portable gas and liquid
separator are components of an engine welder.
25. An integrated portable arc welder comprising: a. a housing that
at least partially contains an internal combustion engine, an
electric current generator and a welding circuit, said electric
current generator at least partially connected to said internal
combustion engine to be at least partially driven thereby, said
welding circuit forming an arc welding current during an arc
welding process from current generated by said electric generator;
and, b. a portable exhaust gas separator at least partially
connected to said internal combustion engine to at least partially
receive exhaust gas generated by said internal combustion engine
during the operation of said internal combustion engine, said
exhaust gas separator at least partially removing liquid from said
exhaust gas and at least partially separating a shielding gas from
said exhaust gas, said exhaust gas separator including a condenser
and a gas filter, said shielding gas at least partially used during
said arc welding process to at least partially shield a weld metal
formed during said arc welding process, said shielding gas includes
a majority weight percent of carbon dioxide.
26. The portable welder as defined in claim 25, wherein said
portable exhaust gas separator is at least partially contained in
said housing.
27. The portable welder as defined in claim 25, wherein said
portable exhaust gas separator is at least partially powered by
said current generated by said electric current generator.
28. The portable welder as defined in claim 26, wherein said
portable exhaust gas separator is at least partially powered by
said current generated by said electric current generator.
29. The portable welder as defined in claim 25, wherein said
portable exhaust gas separator includes a gas compressor to at
least partially compress said shielding gas, said gas compressor is
at least partially powered by said current generated by said
electric current generator.
30. The portable welder as defined in claim 28, wherein said
portable exhaust gas separator includes a gas compressor to at
least partially compress said shielding gas, said gas compressor is
at least partially powered by said current generated by said
electric current generator.
31. The portable welder as defined in claim 29, including a gas
cylinder fluidly connected to said air compressor and a pressure
monitor to monitor a pressure in said gas cylinder, said pressure
monitor designed to generate a control signal to activate or
deactivate said air compressor based at least partially on a
detected air pressure level in said gas cylinder.
32. The portable welder as defined in claim 30, including a gas
cylinder fluidly connected to said air compressor and a pressure
monitor to monitor a pressure in said gas cylinder, said pressure
monitor designed to generate a control signal to activate or
deactivate said air compressor based at least partially on a
detected air pressure level in said gas cylinder.
33. The portable welder as defined in claim 25, including a welding
circuit that is designed to provide sufficient voltage and current
to a workpiece to cause an electric arc to form between a
consumable electrode and said workpiece, said welding circuit at
least partially controlling at least one welding parameter between
said consumable electrode and said workpiece, said welding
parameter includes a parameter selected from the group consisting
of voltage, current, energy, power, polarity, current wave form or
combinations thereof.
34. The portable welder as defined in claim 32, including a welding
circuit that is designed to provide sufficient voltage and current
to a workpiece to cause an electric arc to form between a
consumable electrode and said workpiece, said welding circuit at
least partially controlling at least one welding parameter between
said consumable electrode and said workpiece, said welding
parameter includes a parameter selected from the group consisting
of voltage, current, energy, power, polarity, current wave form or
combinations thereof.
35. A portable exhaust gas separator designed to be connected to an
exhaust of a portable internal combustion engine of an electric arc
welder to produce a shielding gas for use in an ongoing welding
operation comprising: a. a liquid separating mechanism designed to
remove a majority of water and water vapor from an exhaust gas
generated by said internal combustion engine, said liquid
separating mechanism including a condenser, a dehumidifier, a
coalescing filter, a particulate filter or combinations thereof; b.
a gas separating mechanism to separate an arc welding shielding gas
from the exhaust gas, a majority of said arc welding shielding gas
including a gas selected from the group consisting of carbon
dioxide, carbon monoxide or combinations thereof, said gas
separating mechanism including a gas filter, a scrubber, a gas
absorber, a gas adsorber or combinations thereof; and, c. a
shielding gas compressor to at least partially compress said
shielding gas.
36. The portable exhaust gas separator as defined in claim 34,
wherein said portable exhaust gas separator is releasably
connectable to said internal combustion engine.
37. A method of generating a shielding gas for use in an ongoing
arc welding process from an exhaust gas of an internal combustion
engine of a portable electric arc welder comprising: a. generating
an exhaust gas from an exhaust of said internal combustion engine
during the operation of said electric arc welder; b. connecting a
portable gas and liquid separator to said exhaust of said internal
combustion engine; c. removing at least a majority of water and
water vapor from said exhaust gas by said portable gas and liquid
separator; d. separating said shielding gas from said exhaust gas
by said portable gas and liquid separator, said shielding gas
including a gas selected from the group consisting of carbon
dioxide, carbon monoxide or mixtures thereof; and, e. supplying at
least a portion of said shielding gas during said ongoing arc
welding process to at least partially shield a weld metal formed
during said arc welding process.
38. The method as defined in claim 36, wherein said portable gas
and liquid separator are components of said electric arc
welder.
39. The method as defined in claim 36, wherein said portable gas
and liquid separator is at least partially powered by current
generated by said electric arc welder.
40. The method as defined in claim 37, wherein said portable gas
and liquid separator is at least partially powered by current
generated by said electric arc welder.
Description
[0001] The invention relates to the art of welding with an electric
arc and more particularly to an arc welder that is at least
partially supplied a shielding gas from a source other than a
shielding gas cylinder and even more particularly to an arc welder
that is at least partially powered by an engine welder and the
exhaust from the engine welder is at least partially used as a
shielding gas.
INCORPORATION BY REFERENCE
[0002] The present invention incorporates the use of engine welders
of the general type described in U.S. Pat. Nos. 6,296,027 and
6,172,332, United States Patent Application Publication
No.2003/155,339 published on Aug. 21, 2003 entitled "Screw Air
Compressor for a Welder", and U.S. patent application Ser. No.
10/390,436 filed Mar. 17, 2003 entitled "Self-Contained Integrated
Welder/Generator and Compressor."
BACKGROUND OF THE INVENTION
[0003] Arc welders are typically powered by plugging the arc
welding machine into an electrical outlet or having the arc welder
equipped with a gas powered electric generator. Arc welders that
are designed to receive power from an electric outlet are limited
to use in a location that has an electric outlet which is rated to
supply the needed current for operation of the arc welder.
Operators of such arc welders need extension cords to increase the
mobility of such arc welders. When the arc welder is used in a
remote location or in a location that is not readily accessible to
a power outlet or a power outlet having a needed current rating,
the arc welder must be equipped with its own power source, such as
a gas electric generator, to supply the required power to the arc
welder. The engine powered generator is typically designed to be
powered by an engine that consumes a standard petroleum fuel source
such as gasoline or diesel fuel.
[0004] In many arc welding procedures, a shielding gas is required.
Typically, the shielding gas is supplied from gas cylinder. On some
of the larger engine welding units, the gas container is secured to
the housing of the engine welder. For smaller welding units, the
gas container has to be separately transported with the welding
unit. These gas cylinders are typically made of metal, and when
filled with shielding gas, can weigh over 100 pounds. As a result,
the weight of the gas cylinder increases the difficulty in moving
an engine welder that has the gas container connected thereto. For
the smaller welding units, the transport of the heavy gas container
poses its own difficulties when being transported to the welding
site.
[0005] The requirement that a particular welding operation require
shielding gas can also pose problems when the gas in the container
is exhausted. In such circumstances, the empty container has to be
replaced with a new gas filled cylinder. The replacement of the gas
container is both difficult and time consuming. If no other gas
cylinders are available, the welding operation must be delayed
until a gas filled cylinder is acquired.
[0006] In view of the problems associated with gas shielded arc
welding units, there is a need for an alternative or backup source
of shielding gas for gas shielded arc welding systems that is
environmentally friendly, can be safely used in a wide variety of
locations, and is simple to use.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a method and apparatus of
arc welding together metal plates, and more particularly a method
and apparatus for gas shielded arc welding that at least partially
uses the exhaust from a fuel powered engine as shielding gas for
the arc welding procedure.
[0008] In accordance with one aspect of the present invention,
there is provided a welder/generator that includes a housing to
protect the internal components of the welder. At least partially
protected by the housing is a fuel powered engine and an electric
generator. The fuel powered engine runs the electric generator
which in turn produces electricity for the arc welder. The electric
generator is selected to produce electricity for various types of
arc welders such as, but not limited to, TIG welders, plasma arc
welders, SAW welders, MIG welders, STT and other waveform welders.
Electric circuitry can be included within the housing to control
the amount of current, voltage, power and/or the waveform of
current directed to the electrode of the welder. A fuel tank is
typically provided within the housing to supply fuel to the fuel
powered motor. The fuel tank can be positioned in various areas
within the housing, but is generally positioned at or near the base
of the housing or engine welder. A filler tube is typically
connected to a portion of the fuel tank and extends upwardly from
the fuel tank and through a portion of the housing to enable an
operator to refill the fuel tank. The filler tube and fuel tank can
be made from one or multiple pieces of material. The filler tube
and fuel tank are typically made of a durable material such as, but
not limited to, plastic and/or a metal material. The engine welder
typically includes a control panel to operate various internal
components of the welder and/or to provide connectors to various
components of the welder. A fixed or adjustable exhaust pipe for
the fuel power engine can be included on the engine powered welder.
These and other standard components of an engine driven welder are
disclosed in U.S. Pat. Nos. 6,172,332; 6,263,926 and 6,296,027,
which are incorporated herein by reference. The engine welder
housing can also include one or more storage compartments and/or
holders adapted to store and/or hold various welding tools, air
tools, maintenance tools, electrodes, coolant, gas cylinders and/or
other supplies on or within the housing. One non-limiting
arrangement of the one or more storage compartments and/or holders
that can be used is disclosed in U.S. Pat. No. 6,596,972, which is
incorporated by reference. The engine welder can be transported by
a welding carriage; however, this is not required. One non-limiting
welding carriage which can be used is disclosed in Assignee's U.S.
patent application Ser. No. 09/411,106, filed Oct. 4, 1999, which
is incorporated herein by reference. The engine powered welder can
also include a filler tube and fuel tank arrangement that includes
a fuel gauge to monitor the fuel level in the filler tube and/or
fuel tank; however, this is not required. The fuel gauge, when
used, enables an operator to monitor fuel levels within the filler
tube and/or fuel tank to enable an operator to anticipate when the
engine welder needs to be refueled and/or to notify an operator
during the refueling process of the fuel tank when the fuel tank is
filled, thereby avoiding spillage and waste of fuel. The minimizing
of spillage can reduce damage to the welder and/or components about
the welder, and the time and money required for clean-up of the
spilled fuel. One non-limiting configuration of the filler tube and
fuel tank that can be used is disclosed in U.S. Pat. Nos.
6,172,332; 6,263,926; 6,296,027; and 6,619,337, which are
incorporated herein by reference. A grommet or insert can also be
used in the fueling cavity of the housing. The grommet or insert,
when used, is designed to at least partially seal the region about
the fueling cavity to inhibit and/or prevent fluids from entering
the interior of the housing. Non-limiting configurations of a
grommet or insert that can be used are disclosed in U.S. Pat. Nos.
6,172,332; 6,263,926; 6,296,027; and 6,619,337. An air compressor
can be at least partially positioned in the housing to generate
compressed air for the operation of air powered tools. Non-limiting
configurations of a welding housing that incorporates an air
compressor are disclosed in U.S. Pat. No. 6,051,809, Assignee's
U.S. patent application Ser. No. 10/390,436 filed Mar. 17, 2003,
and United States Patent Application Publication No. 2003/155,339
published on Aug. 21, 2003. In one embodiment of the invention, the
exhaust from the fuel powered engine is at least partially directed
to the arc welding gun to be used as a shielding gas during an arc
welding procedure.
[0009] In accordance with another and/or alternative aspect of the
present invention, the arc welder is or can be powered by an
separate fuel powered generator. In this arrangement, the arc
welder can be powered by an existing power source such as a wall
outlet or be powered by being connected to an electric generator.
The welder housing typically includes circuitry to produce a
current and/or voltage for use in various types of arc welding
procedures such as, but not limited to, TIG welding, plasma arc
welding, SAW welding, MIG welding (e.g., Metal Inert Gas Welding,
Metal Active Gas Welding, etc.), STT welding, etc. In one
embodiment of the invention, the exhaust from the separate fuel
powered engine that powers the electric generator is at least
partially directed to the arc welding gun to be used as a shielding
gas during an arc welding procedure.
[0010] In accordance with still another and/or alternative aspect
of the present invention, the arc welder (e.g., engine welder)
includes a separator to separate one or more gases or liquids from
the exhaust gas of an engine so that one or more desired gases can
be used as a shielding gas for an arc welding procedure. The
separator can be secured to an outer surface of the housing of the
arc welder, be positioned partially or fully in the housing of the
arc welder, etc. The exhaust from an engine typically includes
water vapor, carbon dioxide, carbon monoxide, oxygen, nitrogen,
sulfur compounds and other types of gases. During a welding
procedure, the shielding gas is typically designed to shield the
weld metal from oxygen and water vapor in the air. Because oxygen
and water vapor typically exist in the exhaust gas of an engine, it
is desirable to scrub and/or separate the undesired materials
(e.g., oxygen, water, sulfur compounds, hydrocarbon compounds,
etc.) from the exhaust gas prior to directing to the gas to the
welding melting for purposes of shielding the weld metal from the
atmosphere. In one embodiment of the invention, the separator is
designed to pass carbon dioxide and/or carbon monoxide to be used
as shielding gas and to separate out a majority percentage of the
other components from the exhaust gas. In one aspect of this
embodiment, the separator filters out a majority of the nitrogen,
the water and water vapor and oxygen from the exhaust gas so as to
minimize the amount of these components in the shielding gas. In
one particular design, the separator filters out or removes
substantially all the nitrogen from the exhaust gas. In another
and/or alternative design, the separator filters out or removes
substantially all the water and water vapor from the exhaust gas.
In still another and/or alternative design, the separator filters
out or removes substantially all the oxygen from the exhaust gas.
In a further and/or alternative aspect of this embodiment, the
separator primarily allows carbon dioxide in the exhaust gas to
pass a shielding gas. In still a further and/or alternative aspect
of this embodiment, the separator primarily allows carbon monoxide
in the exhaust gas to pass a shielding gas. In another and/or
alternative embodiment of the invention, the separator includes a
gas filter to at least partially separate the gases in the exhaust
gas. In one aspect of this embodiment, the filter includes carbon,
silicon gel, potassium permanganate, hopcalite, molecular sieves,
PTFE porous membranes, etc. In still another and/or alternative
embodiment of the invention, the separator includes a water
absorbing and/or adsorbing compound to at least partially separate
water from the exhaust gas. In yet another and/or alternative
embodiment of the invention, the separator includes a condenser,
dehumidifier, coalescing filters, particulate filters, etc. to at
least partially separate water and/or gases from the exhaust gas.
The materials that form the coalescing filters and/or particulate
filters, when used, can include bonded microfiber such as, but not
limited borosilicate glass; however, other materials can be used.
In still yet another and/or alternative embodiment of the
invention, the separator includes a scrubber to at least partially
separate water and/or gases from the exhaust gas. In a further
and/or alternative embodiment of the invention, the separator
separates liquid (e.g., water, etc.) and waste gas (e.g., sulfur
compounds, lead compounds, hydrocarbons, hydrogen, oxygen, etc.)
from the exhaust gas and primarily directs carbon dioxide and/or
carbon monoxide from the exhaust gas that is to be used as a
shielding gas. In one aspect of this embodiment, the waste gas is
at least partially passed through a filter.
[0011] In accordance with yet another and/or alternative aspect of
the present invention, a separator is used to separate one or more
gases or liquids from the exhaust gas of an engine so that one or
more desired gases can be used as a shielding gas for an arc
welding procedure. In this aspect of the invention, the separator
is a separate component from the arc welder. The separator can be
designed to be connected to the exhaust pipe of an engine welder
that does not include a separator. In addition, the separator can
be designed to be connected to the exhaust pipe of another engine
(e.g. fuel powered generator, fuel powered air compressor, fuel
powered vehicle, etc.). Once the separator is connected to the
exhaust pipe, the filtered and/or separated gas that can be used as
a shielding gas can be directed to a shielding gas inlet of an arc
welder and/or directly to the welding gun. Typically the separator
is connected to the exhaust pipe of an engine, arc welder, welding
gun, etc. by a pipe, tube, etc. Typically, at least a portion of
the pipe, tube, etc, is flexible to simplify the connection and/or
disconnection of the separator from the engine, arc welder and/or
torch gun. The exhaust from an engine typically includes water
vapor, carbon dioxide, carbon monoxide, oxygen, nitrogen, sulfur
compounds and other types of gases. During a welding procedure, the
shielding gas is typically designed to shield the weld metal from
oxygen and water vapor in the air. Because oxygen and water vapor
typically exist in the exhaust gas of an engine, it is desirable to
scrub and/or separate the undesired materials (e.g., oxygen, water,
sulfur compounds, nitrogen compounds, hydrocarbon compounds, etc.)
from the exhaust gas prior to directing to the gas to the welding
melting for purposes of shielding the weld metal from the
atmosphere. In one embodiment of the invention, the separator is
designed to pass carbon dioxide and/or carbon monoxide to be used
as shielding gas and to separate out a majority percentage of the
other components from the exhaust gas. In one aspect of this
embodiment, the separator filters out a majority of the nitrogen,
the water and water vapor and oxygen from the exhaust gas so as to
minimize the amount of these components in the shielding gas. In
one particular design, the separator filters out or removes
substantially all the nitrogen from the exhaust gas. In another
and/or alternative design, the separator filters out or removes
substantially all the water and water vapor from the exhaust gas.
In still another and/or alternative design, the separator filters
out or removes substantially all the oxygen from the exhaust gas.
In a further and/or alternative aspect of this embodiment, the
separator primarily allows carbon dioxide in the exhaust gas to
pass a shielding gas. In still a further and/or alternative aspect
of this embodiment, the separator primarily allows carbon monoxide
in the exhaust gas to pass a shielding gas. In another and/or
alternative embodiment of the invention, the separator includes a
gas filter to at least partially separate the gases in the exhaust
gas. In one aspect of this embodiment, the filter includes an
activated carbon filter. In still another and/or alternative
embodiment of the invention, the separator includes a water
absorbing and/or adsorbing compound to at least partially separate
water from the exhaust gas. In yet another and/or alternative
embodiment of the invention, the separator includes a condenser
and/or dehumidifier to at least partially separate water and/or
gases from the exhaust gas. In still yet another and/or alternative
embodiment of the invention, the separator includes a scrubber to
at least partially separate water and/or gases from the exhaust
gas. In a further and/or alternative embodiment of the invention,
the separator separates liquid (e.g., water, etc.) and waste gas
(e.g., sulfur compounds, lead compounds, hydrocarbons, hydrogen,
nitrogen compounds, oxygen, etc.) from the exhaust gas and
primarily directs carbon dioxide and/or carbon monoxide from the
exhaust gas that is to be used as a shielding gas. In one aspect of
this embodiment, the waste gas is at least partially passed through
a filter. In still a further and/or alternative embodiment of the
invention, the separator is a portable device that can be
conveniently conveyed to a welding site for use with an arc
welder.
[0012] In accordance with still yet another and/or alternative
aspect of the present invention, a gas compressor is used in
conjunction with the separator to at least partially compress or
pressurize the shielding gas from the separator. The gas compressor
can be attached or located at least partially in the housing of an
arc welder (e.g., engine welder, etc.) or be separate from the arc
welder. When the gas compressor is attached or located at least
partially in the housing of an arc welder, the gas compressor is
typically powered by the arc welder (e.g. belt drive, gear drive,
electric powered, etc.). When the gas compressor is a separate
component from the arc welder, the gas compressor is typically
powered by an electric motor or fuel powered motor. If the gas
compressor is powered by a gas powered motor, the exhaust from the
gas powered motor can be directed into the gas separator. If the
gas compressor is powered by electricity that is generated by a
generator powered by a fuel powered motor, the exhaust from the
fuel powered motor can be directed into the gas separator. The gas
compressor can be any type of gas compressor (e.g., piston or
reciprocating compressor, rotary or screw compressor, centrifugal
or axial compressor, etc.). In one embodiment of the invention, the
gas compressor directs compressed gas into a container that is
later used to supply shielding gas during an arc welding procedure.
In one aspect of this embodiment, the gas compressor is used to at
least partially fill a gas container which can be fluidly detached
from the gas compressor and subsequently fluidly connected to a
shielding gas line for an arc welder. In this aspect of the
invention, one or more gas containers can be at least partially
filled for later use in an arc welding process. In another and/or
alternative embodiment of the invention, the gas compressor directs
compressed gas into a container that is being used to supply
shielding gas during an arc welding procedure. In one aspect of
this embodiment, the gas compressor is used to at least partially
refill a gas container which is being used to supply shielding gas
for an arc welder. In this aspect of the invention, one or more gas
containers are at least partially refilled during an arc welding
process. Typically in this arrangement, a pressure valve is used to
monitor the pressure in the one or more gas containers. When the
pressure monitor indicates that the pressure in the container has
fallen below a certain pressure threshold, a signal can be sent to
a controller to activate the gas compressor and/or open a valve
between the gas compressor and the container to enable compressed
shielding gas to be refilled in the container. The pressure monitor
can also be used to send a signal to a controller when a pressure
level in one or more of the containers has been reached to
deactivate the gas compressor and/or close a valve between the gas
compressor and the container to terminate the flow of compressed
shielding gas into the container. In still another and/or
alternative embodiment of the invention, when the gas separator is
fluidly connected to a gas compressor, a valve is typically
positioned between the gas separator and compressor. The valve is
generally used to direct shielding gas from the gas separator to
the gas compressor when the gas compressor is in operation and
expels, releases or otherwise redirects the shielding gas from the
gas separator when the gas compressor is not operating or is unable
to receive gas for compression.
[0013] The primary object of the present invention is the provision
of an arc welding system and method which forms a high quality weld
bead between two metal plates by an gas shielded arc welding
procedure.
[0014] Another and/or alternative object of the present invention
is the provision of an arc welding system and method which is
environmentally friendly.
[0015] Still another and/or alternative object of the present
invention is the provision of an arc welding system and method
which reduces air pollution during operation.
[0016] Yet another and/or alternative object of the present
invention is the provision of an arc welding system and method
which is portable and can be used in a wide variety of
environments.
[0017] Still yet another and/or alternative object of the present
invention is to provide an arc welder that is more convenient and
easier to operate.
[0018] A further and/or alternative object of the present invention
is to provide an engine welder which is easier to set up and/or
transport to various locations.
[0019] Still a further and/or alternative object of the present
invention is the provision of an arc welding system and method that
includes at least partially uses an exhaust gas from a fuel powered
motor as a shielding gas for an arc welding procedure.
[0020] Yet a further and/or alternative object of the present
invention is the provision of an arc welding system and method that
includes a gas separator to at least partially separate shielding
gas from an exhaust gas of a fuel powered engine.
[0021] Still yet a further and/or alternative object of the present
invention is to provide a gas compressor to at least partially
refill a shielding gas container with shielding gas that at least
partially originated from an exhaust gas of a fuel powered
engine.
[0022] Yet a further and/or alternative object of the present
invention is to provide a pressure monitoring system that monitors
and/or controls the pressure in one or more shielding gas
containers.
[0023] These and other objects and advantages will become apparent
to those skilled in the art upon reading the following description
taken together with the preferred embodiment disclosed in the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Reference may now be made to the drawings, which illustrate
various preferred embodiments that the invention may take in
physical form and in certain parts and arrangement of parts
wherein:
[0025] FIG. 1 provides a schematic representation of an integrated
arc welder that is powered by a engine driven electric generator
and has a self generating shielding gas supply from the exhaust of
the fuel powered engine in accordance with the invention;
[0026] FIG. 2 provides a schematic representation of an arc welder
that is powered by a engine driven electric generator and a
shielding gas from the exhaust of the fuel powered engine is at
least partially compressed into a gas container in accordance with
the invention;
[0027] FIG. 3 provides a schematic representation of a
non-integrated arc welder that is powered by a engine driven
electric generator and has a shielding gas supply from the exhaust
of the fuel powered engine that is separate from the arc welder in
accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring now to the drawings wherein the showings are for
the purpose of illustrating preferred embodiments of the invention
only and not for the purpose of limiting the same, FIG. 1
illustrates an electric arc welder 10 for welding together a
workpiece 20. The arc welder 10 is connected to a welding gun, not
shown, that includes a welding head 30. The electric arc welder 10
directs a current wave form to the welding nozzle 40 and workpiece
20 via positive and negative electrical connections 12, 14,
respectively. The welding head 30 includes a nozzle 40 that
facilitates in directing a consumable electrode 50 toward workpiece
20. The consumable electrode can be a solid wire electrode, a cored
electrode, a coated electrode, etc. If the consumable electrode is
a cored and/or coated electrode, the consumable electrode can
include alloy agents and/or fluxing agents. The consumable
electrode 50 is unwound from wire roll 60 and is fed to the welding
gun and through the welding head nozzle 40 as indicated by the
arrows. As can be appreciated, if the consumable electrode is a
stick electrode, the stick electrode is not wound on a reel. A
welding wire feeder 70 controls the feed rate of the consumable
electrode 50 during the welding process. The wire feeder receives a
control signal and/or operating current from the electric arc
welder via control line 72. A shielding gas is supplied to the
welding head nozzle 30 by a gas tube 80 that is connected to a
shielding gas cylinder 90. A shielding gas controller, not shown,
is typically used to control the flow rate of the shielding gas to
the workpiece during the welding process. The arc welder is powered
by an electric generator 100 that is powered by a fuel powered
engine 110 (e.g., diesel engine). The electric generator generates
a current (e.g. alternating current, direct current) and wires 102,
104 electrically connect the generated current to the electric arc
welder. During the operation of the fuel powered engine, a cooling
fan 112 is typically used to cool the engine. The engine also
includes an exhaust pipe 114 that is used to convey exhaust gases
from the fuel powered engine.
[0029] The engine welder illustrated in FIGURE is typically a
self-contained, portable and fully-integrated welder/generator. The
engine welder typically includes a housing, not shown, that is
designed to encase at least a portion of the internal components of
the engine welder. The housing typically includes one or more fluid
accesses used to add coolants, lubricants, etc. to the engine
located in the housing. The housing also typically includes a fuel
cap that is used to close the opening into the filler tube that is
used to fill the fuel tank of the engine welder. A grommet can be
positioned about the fueling cap. The housing also typically
includes a motor access panel that allows a user access to the
internal components of the engine welder. One or more sides of the
housing typically include air vents to allow air flow through the
housing so as to facilitate in cooling the internal components of
the housing. The housing can include one or more compartments that
provide a storage area for welding tools, welding supplies etc. The
front face or panel of the housing also typically includes various
switches, knobs, indicator lights, and meters and gauges that are
used to monitor and/or control the operation of the engine welder
(e.g., an on/off key slot, a start button for the internal
combustion engine, one or more circuit breakers, a light, voltage
and/or current meters, welding current settings, wire feeder
settings, warning indicators, etc.). The front panel of the housing
also includes electrical connectors that are used to connect a
welding gun, wire feeder and/or other electrical equipment to the
engine welder (e.g., electrical connections 12, 14, control line
72, etc.). The housing can also include an air compressor switch to
activate and deactivate an air compressor in the housing and one or
more compressed air outlets that can be used to supply compressed
air to various types of air power tools (e.g., nail gun, paint gun,
pressure washer, sand blaster, etc.).
[0030] As indicated above, the engine welder includes an internal
combustion engine 10 mounted in the housing. The internal
combustion engine is typically provided with an air cleaner, a
muffler 116 connected to exhaust pipe 114, an oil filler tube, a
battery to start the engine, radiator and radiator fan 112 to cool
the engine. A fuel tank is also typically located in the housing to
supply fuel to the engine. Typically, the fuel tank is secured to
the bottom of the housing. Positioned on the top region of the fuel
tank is a filler tube which extends upwardly from the fuel tank and
to a tube access opening in the housing that is used to fill the
fuel tank with fuel. The housing of the engine welder may include a
fuel level monitor to monitor the level of fuel in the fuel tank.
The electric current generator 100 is also typically mounted within
the housing. The electric current generator is connected to the
internal combustion engine 110 by a motor shaft 118. The motor
shaft is typically directly connected to electric current generator
100; however, a gear box and/or belt drive, not shown, can be
inserted therebetween to control and/or regulate the speed at which
the electric current generator is operated by the internal
combustion engine. In one particular, non-limiting arrangement, the
internal combustion engine is a 500 or 700 amp water cooled and/or
air cooled engine. The engine is designed to operate at 1800 RPM
when the current output is set at least at 500 amps. The auxiliary
power provided by the electric current generator is about 60 hertz
and about 1-20 kW so as to be able to run standard power tools and
lights. As can be appreciated, other sized engines and/or
alternators can be used. Typically located in the housing is the
electrical circuitry used to generate the arc currents of the
engine welder through electrical connectors 12, 14. Typically the
power from the electric generator is transformed to create a 120V
and/or 240V power source. One non-limiting design of an engine
welder that can be used in the present invention is similar to that
of the RANGER series of engine welders offered by The Lincoln
Electric Company. As can be appreciated, many other configurations
of engine welders can be used.
[0031] As shown in FIG. 1, a exhaust supply pipe 120 is connected
to muffler 116. The exhaust supply pipe directs exhaust gas to an
exhaust gas separator 130. The exhaust gas separator is designed to
remove most, if not all, water and other liquids from the exhaust
gas and direct the liquids to a liquid disposal line 140. As shown
in FIG. 1, the liquid disposal line can be connected to a liquid
receptacle 142 that can be use to dispose of the captured liquid at
a later time; however, this is not required. The exhaust gas
separator is also designed to separate shielding gas (e.g., carbon
dioxide, carbon monoxide, etc.) from the exhaust gas that directs
the shielding gas through shielding gas line 150. Typically the
separator allows carbon dioxide and/or carbon monoxide to be used
as shielding gas and separates out a majority volume percentage of
the other components in the exhaust gas. As a result, the separator
filters out a majority of the nitrogen, the water and water vapor
and oxygen from the exhaust gas so as to minimize the amount of
these components in the shielding gas. The shielding gas line 150
can be directly connected to gas tube 80 to provide a shielding gas
to the workpiece. As shown in FIG. 1, the shielding gas line to
connected to a shielding gas cylinder 90. FIG. 1 illustrates that
the shield gas separated by the exhaust gas separator is primarily
carbon dioxide. The remaining gas from the exhaust gas is expelled
from the exhaust gas separator though waste gas line 160. The waste
gas can be stored in a gas receptacle 162 for later disposal or
expelled into the atmosphere. Typically the waste gas is expelled
into the atmosphere. The waste gas may be passed through a gas
filter; however, this is not required. The exhaust gas separator
can include one or more mechanisms to separate the gasses and
liquids from the exhaust gas. Such mechanisms can include, but are
not limited to, filters, condensers, dehumidifiers, scrubbers,
absorbers/absorbers, etc. The mechanisms can be chemical separation
mechanisms, mechanical separation mechanisms and/or electric
separation mechanisms. If electrical energy is required to operate
one or more of the separation mechanisms, the electrical power can
be provided by electric generator 100. Typically the components of
the exhaust gas separation system are primarily housed within the
housing of the engine welder; however, this is not required.
[0032] Referring now to FIG. 2, there is provided a modification to
the shielding gas recovery arrangement of FIG. 1. As illustrated in
FIG. 2, the electric current generator 100 is connected to the
internal combustion engine 110 by a motor shaft 118. The electric
generator generates a current and wires 102, 104 electrically
connect the generated current to the electric arc welder. An
exhaust supply pipe 120 is connected to the exhaust of the
combustion engine 110. The exhaust supply pipe directs exhaust gas
to an exhaust gas separator 130. The exhaust gas separator is
designed to remove most, if not all, water and other liquids from
the exhaust gas and direct the liquids to a liquid disposal line
140. The liquid disposal line can be connected to a liquid
receptacle 142 that can be use to dispose of the captured liquid at
a later time; however, this is not required. The exhaust gas
separator separates shielding gas from the exhaust gas and directs
the shielding gas through shielding gas line 150. The shielding gas
line 150 can be connected to gas tube 80a by a gas valve 170 to
provide a shielding gas to the workpiece. The remaining gas from
the exhaust gas is expelled from the exhaust gas separator though
waste gas line 160. The waste gas can be stored in a gas receptacle
162 for later disposal or expelled into the atmosphere. Typically
the waste gas is expelled into the atmosphere. The waste gas may be
passed through a gas filter; however, this is not required. Valve
170 can also be operated to direct all or a portion of the shield
gas flowing through shielding gas line 150 into a gas compressor
180. The gas compressor can be any type of gas compressor (e.g.,
piston or reciprocating compressor, rotary or screw compressor,
centrifugal or axial compressor, etc.). The gas compressor can be
driven by a belt or gearing arrangement or be operated by an
electric motor. As shown in FIG. 2, the gas compressor is driven by
an electric motor that is powered by electric current generator 100
via power lines 182, 184. A switch 190 can be used to operate the
gas compressor. The switch can be a manual or controlled switch.
The compressed shielding gas from the gas compressor is directed
into line 200 which terminates in control valve 210. The compressed
shielding gas that passes through control valve 210 can be either
directed into a shielding gas cylinder 220 which is designed to
store the shielding gas for later use, or be directed into gas tube
80b to provide a shielding gas to the workpiece. As can be
appreciated, gas tube 80b can be connected to line 200. Typically,
the gas compressor is mounted within housing of the engine welder;
however, this is not required. When switch 190 is used as a manual
switch, the operator manually turns the gas compressor on by the
switch so that the shielding gas generated by the exhaust gas
separator is compressed and flows into gas tube 80b or gas cylinder
220. Valves 170 and/or 210 may be manually controlled valves and/or
automatically controlled valves. When the switch is automatically
controlled, a pressure monitor, not shown, is typically used to
monitor the pressure in line 150, line 200 and/or gas cylinder 220.
The pressure monitor can be used to operate valve 170 and/or valve
210 to control the flow path of the shielding gas generated by the
exhaust gas separator. In one non-limiting control arrangement, the
pressure monitor detects the pressure in line 150. When the
pressure in line 150 reaches or exceeds a certain monitored
pressure, the pressure monitor generates a signal that is used to
direct the flow into tube 80a and/or to compressor 180. If the
shielding gas is directed to compressor 180, the signal generated
from the pressure monitor can be used to cause switch 190 to run
the gas compressor. The signal from the pressure monitor can also
be used to control valve 210 which is used to control the flow of
the compressed shielding gas through tube 80b and/or into gas
cylinder 220. The signal from the pressure monitor can also be used
to activate/deactivate the exhaust gas separator. As can be
appreciated, the control of the valves, exhaust gas separator
and/or compressor can be achieved by a hard wire circuit and/or a
microprocessor. As can also be appreciated, many other control
arrangements can be used.
[0033] As described above, the arrangement in FIG. 2 was depicted
as being part of an engine welder. As can be appreciated, the
arrangement in FIG. 2 can alternatively illustrate the use of an
exhaust gas separator in combination with an electric generator. In
such an arrangement, the electric generator can be used to supply
current to a welder and/or supply power to other types of
electrical devices (e.g., lights, air compressors, electric powered
tools, etc.). In this arrangement, the electric current generator
100 and the combustion engine are separate components from the
welder. When the electric generator is not used to power a welder,
the arrangement disclosed in FIG. 2 is typically used to fill gas
cylinder 220 with compressed shielding gas to later use in a gas
shielded arc welding procedure.
[0034] Referring now to FIG. 3, there is provided another
modification to the shielding gas recovery arrangement of FIG. 1.
As illustrated in FIG. 2, a free standing internal combustion
engine 300 is provided. The internal combustion engine 300 can be
used to power many types of devices (e.g., fan, electric generator,
pump, air compressor, etc.). An exhaust supply pipe 310 is
connected to the exhaust of the combustion engine 300. The exhaust
supply pipe directs exhaust gas to an exhaust gas separator 320.
The exhaust gas separator is designed to remove most, if not all,
water and other liquids from the exhaust gas and direct the liquids
to a liquid disposal line 330. The liquid disposal line can be
connected to a liquid receptacle 332 that can be used to dispose of
the captured liquid at a later time; however, this is not required.
The exhaust gas separator separates shielding gas from the exhaust
gas and directs the shielding gas through shielding gas line 340.
The shielding gas line 340 can be connected to gas receptacle 342
which in turn is connected to tube 80 to provide a shielding gas to
workpiece 20. As can be appreciated, tube 80 can be directly
connected to line 340. As can also be appreciated, one or more
valves can be used to control the flow of shielding gas into tube
80 and/or into gas receptacle 342. The remaining gas from the
exhaust gas is expelled from the exhaust gas separator though waste
gas line 350. The waste gas can be stored in a gas receptacle 352
for later disposal or expelled into the atmosphere. Typically the
waste gas is expelled into the atmosphere. The waste gas may be
passed through a gas filter; however, this is not required. As can
be appreciated, a gas compressor, not shown, can be used to
compress at least a portion of the shielding gas flowing through
line 340. Electric arc welder 10 is shown to be connected to a
welding gun, not shown, that includes a welding head 30. The
electric arc welder 10 directs a current wave form to the welding
nozzle 40 and workpiece 20 via positive and negative electrical
connections 12, 14, respectively. The welding head 30 includes a
nozzle 40 that facilitates in directing a consumable electrode 50
toward workpiece 20. The consumable electrode 50 is unwound from
wire roll 60 and is fed to the welding gun and through the welding
head nozzle 40 as indicated by the arrows. A welding wire feeder 70
controls the feed rate of the consumable electrode 50 during the
welding process. The wire feeder receives a control signal and/or
operating current from the electric arc welder via control line 72.
A shielding gas is supplied to the welding head nozzle 30 by a gas
tube 80. The arc welder is shown to be powered by an external power
source (e.g., wall outlet, electric generator, etc.). As can be
appreciated, the arc welder can be designed to be powered by an
internal electric generator.
[0035] In the embodiment illustrated in FIGS. 2 and 3, the exhaust
gas separator and/or gas compressor, and internal combustion engine
can be connected to a single unit (e.g. contained in a single
housing, attached to a carriage, etc.) so as to simplify the
portability of such components. Alternatively, these components can
be separate components that are designed to be easily connected
together when required.
[0036] In summary, the present invention is particularly directed
to MIG welding or other arc welding procedures that require a
shielding gas. In welding applications where a motor is used to
provide power to an arc welder or where the fuel powered engine is
used to power an auxiliary power supply or air compressor, etc.,
the exhaust from the engine is at least partially converted into a
gas that can be used as the sole shielding gas for an arc welding
procedure or can be mixed with one or more other gases for use as a
shielding gas for an arc welding procedure. The use of exhaust from
the engine for conversion into a shielding gas has the potential to
eliminate the need of shielding gas cylinders. As a result, the
cost, energy and time for transporting, replacing and setting up
the shielding gas cylinders for an arc welding procedure can be
significantly reduced or eliminated by the present invention.
Indeed, the present invention can supply a shielding gas source for
an arc welding procedure at very little cost. The present invention
utilizes an exhaust gas separator that is used to separate out
usable shielding gas or gases from the exhaust gas for use as a
shielding gas. The separator can be a component of the arc welding
such as in an engine welder or be a separate, but portable device.
The separator can include various arrangements (e.g. filters,
absorbers, absorbers, etc.) to facilitate in at least partially
cleaning the unused exhaust gas so as to make the invention an
environmentally desirable or green invention. The present invention
also envisions the use of one or more control arrangements to
control the supply of shielding gas from the exhaust gas. The
present invention further envisions the use of a compressor and
control arrangement that can be used to store the produced
shielding gas in a gas cylinder for later use.
[0037] The invention has been described with reference to a
preferred embodiment and alternates thereof. It is believed that
many modifications and alterations of the embodiment disclosed will
readily suggest themselves to those skilled in the art upon reading
and understanding the detailed description of the invention. It is
intended to include all such modifications and alterations in so
far as they come within the scope of the present invention.
* * * * *