U.S. patent application number 13/833968 was filed with the patent office on 2013-08-08 for torch for electric arc welding system.
This patent application is currently assigned to LINCOLN GLOBAL, INC.. The applicant listed for this patent is LINCOLN GLOBAL, INC.. Invention is credited to Jeffrey L. KACHLINE.
Application Number | 20130200058 13/833968 |
Document ID | / |
Family ID | 37461474 |
Filed Date | 2013-08-08 |
United States Patent
Application |
20130200058 |
Kind Code |
A1 |
KACHLINE; Jeffrey L. |
August 8, 2013 |
TORCH FOR ELECTRIC ARC WELDING SYSTEM
Abstract
A torch for connection to an electric arc welding system having
a wire feeder, a power source and a weld process controller for the
power source. The torch being connected to the front end of a
welding gun, which gun has a rear end with a first unique component
of a connector. The welding system has a second component of the
connector matching the first component. The gun has a communication
channel extending from the torch to the first component for
transmitting data to the welding system through the connector. The
torch has a memory with an identification code outputted on the
communication channel to the first component and the system has a
decoder circuit connected to the second component and responsive to
a selected identification code.
Inventors: |
KACHLINE; Jeffrey L.;
(Highland Heights, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LINCOLN GLOBAL, INC.; |
City of Industry |
CA |
US |
|
|
Assignee: |
LINCOLN GLOBAL, INC.
City of Industry
CA
|
Family ID: |
37461474 |
Appl. No.: |
13/833968 |
Filed: |
March 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11210286 |
Aug 25, 2005 |
8431862 |
|
|
13833968 |
|
|
|
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Current U.S.
Class: |
219/138 |
Current CPC
Class: |
B23K 9/1056 20130101;
B23K 9/28 20130101; B23K 9/1006 20130101; B23K 9/32 20130101; B23K
9/095 20130101; B23K 9/067 20130101 |
Class at
Publication: |
219/138 |
International
Class: |
B23K 9/32 20060101
B23K009/32 |
Claims
1. A welding system comprising: a wire feeder apparatus, a supply
of wire wherein the wire is fed through the wire feeding apparatus,
a gun through which the wire passes, said gun having a memory
switch; and a control device which controls the feeding of the wire
through the feeding apparatus based upon input from a user input
device positioned on at least one of the wire feeding apparatus and
the brazing wire gun, wherein said control device has at least one
memory space, said memory switch being configured with said at
least one memory space for recording at least one welding parameter
to said memory space.
2. The system of claim 1, wherein the at least one welding
parameter includes at least one of a diameter of said wire, a
material of said wire, a wire feed speed, and a duration of a wire
feeding operation can be input by said user input device.
3. The system of claim 1, wherein said gun comprises a trigger
portion to activate said wire feeding operation.
4. The system of claim 3, wherein said trigger portion has a first
position corresponding to a first wire feed speed and a second
position which corresponds to a second wire feed speed.
5. The system of claim 3, wherein said trigger portion controls
said wire feeding operation based on the movement of said trigger
portion, wherein there is a non-linear relationship between the
movement of the trigger portion and the wire feed speed of the
wire.
6. The system of claim 1, wherein said gun comprises a trigger to
activate the feeding of said wire and at least one second control
portion which controls a speed of the feeding of said wire.
7. The system of claim 1, wherein said at least one brazing
parameter includes feeding the brazing wire through the brazing
wire feeding apparatus.
8. The brazing apparatus of claim 7, wherein said at least one
parameter is one of wire feed speed, a length of wire, and a wire
feed duration.
9. A system, comprising: a wire feeding apparatus, a supply of wire
wherein the wire is fed through the wire feeding apparatus, a gun
through which the wire passes, and a control device which controls
the feeding of the wire through the feeding apparatus based upon
input from a user input device positioned on at least one of the
wire feeding apparatus and the wire gun, wherein said wire gun
comprises a trigger to activate said wire feeding operation, and
wherein said trigger controls said wire feeding operation based on
the movement of said trigger, said control device having at least
one memory space and at least one memory button configured with
said memory space to any one of select or store a plurality of
process parameters.
10. The system of claim 9, wherein at least one of a diameter of
said wire, a material of said wire, a wire feed speed for said
wire, and a duration of a wire feeding operation can be input by
said user input device.
11. The system of claim 10, wherein said trigger portion has a
first position corresponding to a first wire feed speed and a
second position which corresponds to a second wire feed speed.
12. The system of claim 10, wherein there is a non-linear
relationship between the movement of the trigger portion and the
wire feed speed of the brazing wire.
13. The system of claim 10, wherein said gun controls a speed of
the feeding of said wire.
14. The system of claim 10, wherein said plurality of parameters
includes feeding the wire through the brazing wire feeding
apparatus.
15. The system of claim 14, wherein said plurality of brazing
parameters includes one of wire feed speed, a length of wire, a
wire feed duration and a wire feed pause time.
16. A programmable system comprising: a wire feeding apparatus for
feeding a wire, a gun, and a controller for programming a plurality
of welding operations, said controller controls the feeding of the
wire through the feeding apparatus based upon input from an index
device positioned on at least one of the wire feeding apparatus and
the gun, wherein said gun comprises a trigger to activate said wire
feeding operation, wherein said trigger controls said wire feeding
operation based on the movement of said trigger portion, wherein
each operation is defined by at a plurality of parameters including
at least one of a diameter of said wire, a material of said wire, a
wire feed speed for said wire, and a duration of a wire feeding
operation can be input by said index device, and wherein said
controller comprises at least one memory space configured with said
index device to store said plurality of parameters to program said
apparatus.
Description
PRIORITY DATA & INCORPORATION BY REFERENCE
[0001] This application is a continuation of prior application Ser.
No. 11/210,286, filed Aug. 25, 2005, which is incorporated by
reference in its entirety.
TECHNICAL ART
[0002] The present invention relates to electric arc welding and
more particularly to a unique torch specially designed for
increasing the transfer of intelligence between the torch and an
electric arc welding system adapted to receive the torch.
BACKGROUND OF INVENTION
[0003] The invention involves the design of a unique torch for use
with an electric arc welding system where the torch has special
abilities to communicate with the welding system and the system is
adapted to receive the torch. In Friedl U.S. Pat. No. 6,315,186 a
special designed torch includes an input device and a display
device on the torch itself so that a dedicated line is used to
communicate data from the torch to the electric arc welding system
being used with the torch. The system can identify the torch and
change parameters of the welding process implemented by the welding
system. The parameters are changed on the torch itself and are
communicated by a single communication line to set and select
parameters for the welding system. The alleged novelty is a single
communication line, but not details of the communicated data or the
response of the system to the data. This patent is incorporated by
reference herein for its background technology and for the
description of a torch with an input device, as well as a torch
mounted display device. In a like manner, Kaufman U.S. Pat. No.
6,855,914 is incorporated by reference. The welding system
identifies the impedance of the torch to decide the type of torch
connected to the welding system, whether a push-pull torch or
merely push torch. Identification of the type of torch connected to
the system is used to set a parameter, such as the motor speed for
the wire driven through the gun or torch to the welding operation.
This background patent utilizes the system itself to determine the
type of torch and does not employ the torch as the source of multi
purpose intelligence to control the weld process of the welding
system. These two patents comprise the background to which the
present invention is directed and disclose only primitive
communication between the welding torch and the welding system.
THE INVENTION
[0004] In the welding industry, the term "gun" is used in the
welding industry to describe an elongated, flexible harness called
the "cable" comprising an isolation tube with a rear end
connectable to a welding system of the type including a wire feeder
and power source with controller. The front end of the "gun" has a
torch to perform the welding operation. The terms "torch" and "gun"
are often used interchangeably to mean either the welding head or
the whole unit. In this description the welding head is called a
"torch."
[0005] In accordance with the present invention the torch at the
end of the gun is modified and especially designed to communicate
with a welding system also designed for receiving the special type
of torch. Thus, the torch has a special design and the welding
system has an input terminal structure or receptacle communicated
with special architecture and components in the welding system to
identify the special torch and receive information in digital
format from the torch. The information is used to operate the
controller of the welding system. Consequently, in one feature of
the invention, the torch includes an internal register or memory
having a unique digital identification code or other means to
communicate its identity to a specially designed welding system. By
(a) allowing the torch to identify its unique characteristics
and/or its specific identity and (b) communicating data from the
torch through a digital channel to the welding system, several
unique capabilities are made possible. The special torch and
modified welding system constitute companion components
facilitating communications between the two components for the
purposes of enhancing the overall efficiency of the welding
operation and improving the quality control and inventory
requirements for the torch itself.
[0006] In accordance with one aspect of the invention, the torch is
connected to an electric welding system having a wire feeder with a
feed motor, a power source and a weld process controller for the
power source and the wire feeder to cause a selected welding
process. The torch has a memory device for storing an
identification code unique to the torch and a transmission line or
communication channel to output the identification code in digital
format. A unique receptacle with a plug and receptacle having a
unique pin pattern allows connection of the torch, through an
elongated tube or gun, to the welding system. The welding system to
which the torch is connected by a unique receptacle has a torch
monitoring device with an input terminal connected to the
transmission line or channel when the torch is connected to the
system. This monitoring device has an input decoder circuit to
identify the torch and to activate the monitoring program tailored
to the particular torch being identified. In this aspect of the
invention, the monitoring device includes at least one accumulator
for totaling a first torch use factor based upon a selected weld
parameter or combination of parameters. A circuit is used to enable
the accumulator when a specific torch is connected to the input
terminal of the weld system. The accumulator has an output signal
representing the total of the major parameter. A program selected
by connecting the specific torch creates or outputs a limit value
for the use factor being monitored. A comparator network is
provided with a first input being the accumulator output signal and
a second input being the limit value from the selected program
determined by the actual torch connected to the welding system. The
comparator network creates an action signal when the output of the
accumulator reaches the limit value from the selected program. In
this manner, the torch is connected to the welding system and the
monitor is operated based upon a selected program coordinated with
a particular torch. When a torch use factor being monitored reaches
a given value, an action signal is created. The action signal
indicates a corrective action to be taken, such as changing the
liner of the gun, changing the contact tip of the torch or
replacing and/or refurbishing the total torch. Consequently,
whenever a given torch is connected to the welding system, a
monitor measures one or more use factors. The use factors are
stored until the next use of the particular unique torch.
Ultimately, the torch, either during a single application or
subsequent uses of the same torch, will pass a use factor limit
value to identify an action to be taken, such as maintenance of the
particular torch. In accordance with an aspect of the invention,
the condition of the use factor can be displayed at the monitor or
at a remote location by an hard wire or an ethernet communication
network. Consequently, whenever a torch is applied to the welding
system, the identification code is read by the welding system and
the monitor is initiated to accumulate a use factor or factors for
the particular, unique torch.
[0007] In accordance with another aspect of the present invention,
the torch, with a unique identification stored in memory or
register, can also include a manually operated input device on the
torch itself to create an output signal with digital data
identifying a specific weld process. A communication channel
directs data from the torch to the controller where a circuit
shifts the weld process of the controller. In this manner, an input
set circuit responsive to the digital data from the torch sets the
weld process of the controller to a specific weld process selected
at the torch. In this embodiment of the invention, the weld process
selected at the torch is based upon the type of process and the
diameter and/or type of welding wire for the particular process.
Thus, an operator indexes the torch between weld processes and
diameters or types of wire at the torch itself. Then, the torch
transmits such data from the torch to a set circuit of the
controller so the controller is set to perform the process selected
at the torch. Consequently, the identification code stored in the
torch is used to select the monitor and monitor the operation of
the torch, while the torch itself is used to set the particular
weld process of the controller used for controlling the power
source and/or the wire feeder.
[0008] The object of this aspect of the invention is the provision
of a torch which has an identification code transmitted to the
welding system for actuating a monitor to maintain information
regarding historical use of the torch. Furthermore, the torch is
provided with a process selector so the operator can convert
process data into digital information and transmit such data
through an information channel to the set circuit for the power
source controller of the welding system. Thus, the individual torch
is monitored and the torch is used, alternatively, to control the
actual weld process performed by the welding system.
[0009] In a second embodiment of the invention, the torch does not
have a stored identification code, but it has a communication line
or channel directly attached to the set input circuit of the power
source controller. Consequently, by merely connecting the gun with
a front end torch to the welding system, the communication channel
with the controller is established. The welding system in this
embodiment of the invention does not have a torch monitor, but has
a controller with an input set circuit that can be actuated by a
gun having a particular input communication line or channel
designed to match the receptacle at the input of the welding
system. The rear end of the gun is connected to the wire feeder
using a special connector with matching plug and receptacle.
Consequently, in this second embodiment of the invention, the torch
is merely connected to the electrical welding system. The torch has
a set up device for manually selecting the welding parameters of
the welding process and a line communicating the selected parameter
in digital format to the torch itself. From the torch, the digital
data is directed through a communication line coextensive with the
tube comprising the gun. The line extends from the torch to the
controller to thereby set the parameters from the torch in the
controller to perform the weld process. The set up device can be
separate from the torch to adjust the value of parameters, such as
wire feed speed, current and voltage and accessories, such as the
type of gas. These parameters and accessories are loaded manually
into the set up device which device is then connected to the memory
of the torch. The torch memory device communicates this information
to the input set circuit of the controller in the welding system. A
specially designed torch is necessary, since only a special torch
can have the communication line extending from an internal memory
device storing the parameters through the special receptacle of the
welding system. In another application of this concept, the set up
device is loaded with an identification code which can be used as
defined above to enable the circuit for accepting data when the
torch having such data is used. In accordance with an aspect of the
invention, the set up device is a separate unit that merely
introduces the set parameters and the torch identification code
into a memory, such as through a touch memory button on the torch.
The data is thereby loaded into the torch for subsequent use when
the torch is connected to a welding system. Connection is allowed
by a communication port in a connector on the system. This
connector is unique to the communication line from the torch and
includes a plug and receptacle with a matching unique pin pattern.
By using this second embodiment, other operating features can be
incorporated with the torch.
[0010] In one implementation, a torch can be loaded with a set of
parameters for the weld process. Thus, whenever this torch is
connected to the welding system the controller is automatically set
to perform the desired weld process. This modification has an
advancement where a toggle mechanism on the torch toggles between a
plurality of sets of parameters. Then the parameter set is selected
by the toggle mechanism and is connected to the weld system. The
controller is automatically shifted to the desired parameters.
Another implementation involves a personal parameter setting device
or module. A welder has his own monitor. When he is ready to weld,
he merely loads the parameters from his own module into a torch.
The torch is thereby set to the parameters tailored by the welder.
This loads these personal parameters into the controller by
connecting the torch to the welding system by way of a special
connector at the rear end of the flexible tube or gun.
[0011] A third embodiment of the invention involves a torch for
connection to an electric welding system, as defined above. The
torch has a register with a unique identification code, in digital
format so that the torch is connected by communication channel to
an interface module activated by a given code and/or codes. One
code that activates the interface is the unique code of a
particular torch connected to the welding system. The interface has
an output that sets the weld process parameters. The output channel
of the interface transmits digital data to the controller that has
a set up circuit for storing the transmitted digital data as
control parameters for the power source. Thus, by merely connecting
a particular torch to the welding system, the torch is identified
and is allowed to activate an interface module. This module sets
the parameters in the controller used by the welding system. The
identification code for the torch is in memory or register on the
torch and is directed through a unique connector to the ID terminal
of the interface module. The controller is set in response to the
identification code stored on the individual torch. Another aspect
of such a torch is the setting of the weld parameters on the torch
itself. The parameters are selected and optionally displayed on the
torch; however, they are also communicated to the interface for the
purposes of changing the parameters stored in the interface
modules. Thus, the torch is identified and activates the interface
to operate the controller. As an option, the torch itself is
normally adjusted to change the output parameter of the interface.
Consequently, the torch by being connected to the welding system
activates an interface to set the controller to the desired
parameters, which parameters may or may not be changed manually by
a welder at the torch itself.
[0012] In accordance with a fourth embodiment of the invention, a
unique torch design is provided wherein the torch itself can
include a monitoring system. A first sensor in the torch measures
the level of arc current and a second sensor in the torch also
measures the level of the wire feed speed to the torch. These
measurements multiplied by time are accumulated to create use
factors as explained in connection with the first embodiment. A
memory unit associated with the torch itself stores the use signal
or signals and a monitor reads the use signals. This monitor can be
in the form of a touch memory button. The use factor information is
stored on the torch and is read from the torch or displayed on the
torch. Consequently, the torch can be interrogated to determine how
much use it has experienced and whether it is capable for a
subsequent, long term welding application. By this embodiment of
the invention, the torch carries with it a use history which is
readable directly or indirectly from the torch. This ability to
know the use history of a torch is of substantial benefit for
inventory control. Furthermore, it prevents a torch from being
placed into an application for which it does not have residual life
to complete.
[0013] A fifth embodiment of the invention is a torch with a unique
identification code stored in the torch itself. This code is used
with a controller including a closed loop circuit to control the
weld parameters, such as current and/or voltage and a network to
create a special weld procedure. The torch, with the unique
identification code stored on the torch, creates an output signal
which is decoded for identification by the welding system. Receipt
of the proper code creates a network enabling signal. This can be
accomplished by connecting the lead carrying the unique
identification code from the torch to the welding system. By
attaching the novel torch, the network enabling signal is created
by a decoded identification of the proper torch. This signal
activates the network and converts the controller to the special
weld procedure. In this manner, a particular torch designed for a
given special operation of the controller is the only type of torch
which can activate the special alternative weld procedure. This
embodiment of the invention assures that a special torch is used
when a special welding process is implemented by the welding
system.
[0014] These and other designs of the torch for a welding system
are aspects of the present invention which will be described in
more detail later. The original claims are incorporated by
reference herein as disclosure.
[0015] The primary object of the present invention is the provision
of a torch for an electric welding application, which torch is
coordinated with the welding system. When the torch is connection
to the system, the torch communicates with the welding system to
facilitate accurate monitoring of the torch and/or proper welding
using a specific torch.
[0016] Another object of the present invention is the provision of
a torch, as defined above, which torch has a stored digital
identification code indicative of either the particular torch
itself for the purposes of inventory and maintenance or a type of
torch for the purposes of coordinating the operation of the torch
with the welding system and/or modifying the welding process
performed by the welding system. The use of a novel torch that
communicates with the welding system to perform diverse operations
and function is the overall object of the invention.
[0017] Yet another object of the present invention is the provision
of a torch, as defined above, which torch transmits an
identification code to start a monitor associated with each
individual torch. The monitor stores information based upon
operation of the torch for the purposes of subsequent inventory
and/or maintenance of the torch. Furthermore, such torch, with a
stored identification code, has the desired characteristics
required by a particular welding system to which the torch is
connected and for performing a desired welding process.
[0018] Another object of the present invention is the provision of
a welding torch, as defined above, which welding torch transmits
digital information from the torch to the welding system. The
information is readable only by a dedicated welder having an input
connector comprising a receptacle and port with matching pi
patterns. The connector allows the system to receive and process
transmitted digital information from the torch.
[0019] Still a further object of the present invention is the
provision of a torch, as defined above, which torch includes a
monitor or a torch mounted monitoring device to record and store
the history of a particular torch based upon use factors so a torch
with very little life will not be used in an application requiring
long term operation. Thus, the invention avoids mismatching of a
torch history and the application to which the torch is
intended.
[0020] Still a further object of the present invention is the
provision of a welding torch, as defined above, which welding torch
is used to activate a unique specially designed welding system
through the setting of parameters in the power source controller or
otherwise.
[0021] Yet another object of the invention is the provision of a
torch which is loaded with desired weld parameters so when the
torch is connected to the weld system the system is programmed by
the torch. Thee loaded parameters can be adjusted and carried with
the torch.
[0022] A further object of the invention is the provision of a
torch which can be programmed by an operator with a personalized
set-up unit or module so the operator merely loads a torch when he
is ready to use the torch (any torch) for a given weld process.
[0023] These and other objects and advantages will become apparent
from the following description taken together with the accompanying
drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0024] FIG. 1 is a schematic, combined wiring and block diagram
illustrating a first embodiment of the present invention;
[0025] FIG. 2 is a schematic illustration of certain structures
employed in the embodiment shown in FIG. 1;
[0026] FIGS. 3 and 4 are block diagrams illustrating representative
techniques for loading identification codes into the torch shown in
FIGS. 1 and 2;
[0027] FIG. 5 is a schematic, combined wiring diagram and block
diagram illustrating a second embodiment of the present
invention;
[0028] FIG. 6 is a schematic, combined wiring diagram and block
diagram illustrating a third embodiment of the present
invention;
[0029] FIG. 7 is a schematic, combined wiring diagram and block
diagram illustrating a fourth embodiment of the present invention;
and,
[0030] FIG. 8 is a schematic, combined wiring diagram and block
diagram illustrating a fifth embodiment of the present
invention.
PREFERRED EMBODIMENTS
[0031] In electric arc welding applications, a torch is located on
the front end of an elongated flexible tube called a "gun"
connected by a plug/receptacle with a welding system. Such system
normally includes a wire feeder and a power source provided with a
controller to operate the power source and/or the wire feeder to
move welding wire through the gun and the torch to the welding
operation at a desired wire feed speed with the desired voltage and
current characteristic to perform a specific welding process
dictated by the setting of the controller. The present invention
involves novel torches, each of which is combined with a modified
welding system that accommodates the torch and communicate with the
torch in novel combinations of elements. These torch/welding system
combinations facilitate the welding operation by using intelligence
supplied by the torch. The torches of this invention each have a
special design different from common torches normally used in the
welding industry.
[0032] The first embodiment of the invention is shown in FIGS. 1
and 2 wherein specially designed torch T has a handle, illustrated
as a broomstick type handle 10, with an outwardly extending
gooseneck 12 terminating in a lower nozzle 14 through which welding
wire W is pushed toward workpiece WP to perform a welding process
between welding wire W and the workpiece WP. As is normal in the
welding industry, welding system A is communicated with torch T and
includes a wire feeder 20 having a supply of welding wire 22 pulled
by feed rolls 24 driven at a wire feed speed determined by motor 30
under the control of microprocessor 32. The microprocessor receives
wire feed speed commands through control lead 34 normally connected
to wire feeder 20 and having an internal microprocessor control
chip not illustrated. To provide current for the welding operation,
system A includes power source 40 with controller 42 having output
lead 44 for controlling the operation of the power source and lead
46 for controlling the operation of wire feeder 20. The controller
itself can provide the information on lead 34 to set the speed of
the motor 30 so the desired wire feed speed is used in accordance
with the needs of the particular welding process being performed by
system A. Torch T is connected to the front end of the elongated,
flexible cable or gun G having an outer sheath covering designated
leads 60, 62 which leads constitute a unique structure to the
present invention. Gun G also houses moving welding wire W and
power lead 70 as is common in the welding industry. The rear end of
elongated gun G is connected to system A by special connectors 80a,
80b to accept the special designated lead 60, 62. The connectors
are one unit with a plug and receptacle with matching pin patterns.
The gun also has a trigger lie to start the welding operation. Of
course, the gun also provides a gas passage for shielding gas to be
provided at the welding operation if the welding operation is not
self-shielding. As so far described, torch T and system A are
standard welding components except for the designated lead 60, 62
and the special combined connectors 80a, 80b used to accept the
rear end of gun G carrying not only a wire W, power lead 70 and a
gas conduit, but also designated leads 60, 62. In operation,
controller 52 operates wire feeder 20 and power source 40 for
driving wire W through torch T as a designated welding process is
performed. The process has specific parameters, such as current
voltage and wire feed speed dictated by the setting of controller
42. Into this standard architecture, the present invention is
incorporated.
[0033] In accordance with the invention, torch T includes an
internal memory or storage register 100 for storing an
identification code. The code is indicative of particular unique
torch T. By depressing transit button 102, the unique torch
specific digital code in memory or register 100 is transmitted
through designated line 60 to portion 80a of the combined
connector. This connector is at the input of monitor M for
monitoring the operation of the unique torch T. Monitor M includes
a digital processing device, such as a DSP or microprocessor, to
perform the functions hereinafter explained after receipt of
digital data from controller 42 by way of inputs 110 and 112. Input
110 reads and retrieves appropriate data from wire feeder 20, while
input 112 reads and retrieves appropriate data from controller 42.
This data is processed by monitor M to generate information
regarding the operation of torch T. The torch information is used
for servicing and inventory purposes associated with the particular
unique torch T. Monitor M has an internal digital decoder 130
connected to the input of connector portion 80a. The decoder
outputs on line 130a the identity of the particular torch T
connected to connector portion 80a. This information is generally
related to the specific torch. It is directed by lead 130a to a
select table routine or program 132 so that data on output line 134
identifies unique specific torch T. This information is directed by
line 134a to a look up table 120 storing a multiple of programs,
each of which includes a limit value for a torch of the general
type used as the specific unique torch T. To assure that only that
type of torch is capable of communication with monitor M, line 60
is communicated to a password circuit 140 set to a series of
different types of torches that are capable of activating monitor
M. This type of special torch T is provided by program 142 so that
the information on line 60 passed to the identification digital
decoder 130 is the identity of torch T and the particular type of
the torch. This password of the type of torch can be provided at
register 100 as described in FIG. 3. Monitor M is informed of the
specific torch T and the type having values stored in lookup table
120. Monitor M also includes an internal memory 150 connected by
line 152 to the input decoder circuit 130 to obtain he identity of
the specific torch. Thus, memory 150 stores information specific to
the unique torch T. Memory 150 writes the identification code from
memory 100 into a register and accumulates information developed by
monitor M for the particular torch. The memory 150 has I/O line 154
to input and store information relating to the particular unique
torch T and to output this stored information associated with a
particular torch identified by the input decoding circuit 130. The
stored data of a particular torch is outputted on I/O line 154.
When torch T is a new torch or has been refurbished and therefore
requires clearing of existing stored information in memory 150, the
memory is reset by a program represented by gate 160 having output
line 160a. A reset logic on line 160a resets memory 150 for the
particular torch identified by the digital data on line 152. Gate
160 has a first input line 162 from decoder 164 for decoding the
digital information on line 140a and providing a logic 1 on input
162 for the particular torch T connected to connector portion 80a.
The other input to gate 160 is the logic on line 170 from the reset
program 172. The program produces a logic 1 on line 170 when a new
or refurbished torch T is first used in the combination illustrated
in FIG. 1. Thus, the information on line 154 is the accumulated
information for a particular torch T. When a new torch is used, a
reset signal on line 160a resets memory 150 for the new torch.
Monitor M then monitors the operation of the new unique torch
T.
[0034] Monitor M has an internal program for monitoring the
operation of each specific torch T identified by the code data,
appearing in line 152. The type torch from the input code activates
line 130a to select a program stored in lookup table 120. A variety
of program architecture can be used for monitoring various
conditions of torch T; however, in this first embodiment of the
present invention, as illustrated in FIG. 1, communication line 154
reads the accumulated stored values for the torch identified by
line 152 and writes additions to these stored values. This update
procedure for historical data for unique torch T is obtained by
outputting particular limit values for various parameters
associated with the type of torch selected by password device 140.
These limit values are outputted from lookup table 120 on line 200
and are separated by output circuits, not shown, for value limit
select lines 200a, 200b, 200c and 200n. The data on these lines
control comparator networks 210, 2121, 214, and 216, respectively.
Thus, the comparator networks monitor certain limit values from
lookup table 120 associated with a particular type of torch and
these limit values are used in the output program P of monitor M
for the specific torch T identified by data on line 152. Comparator
networks 210-216 have associated digital accumulators 220, 222, 224
and 226, respectively. In practice, at least one accumulator and
comparator is used for practicing the first embodiment of the
invention; however, preferably several comparators and accumulators
are used so that many historical and operational characteristics of
torch T can be monitored simultaneously. The accumulators are
driven by inputs 230, 232, 234 and 236, respectively, driven by
parameters and/or events. Thus, the action signals on output lines
240, 242, 244 and 246 indicate when the associated comparator
changes logic because the accumulator associated with the
comparator exceeds the limit values outputted from lookup table
120. The action signal logic on lines 240, 242, 244 and 246
activate action identification registers 250, 252, 254 and 256,
respectively. The state of these action registers is shown on
associated display devices 250a, 252a, 254a and 256a, preferably
located on a remote console; however, they can be associated with
the welding system or actually displayed on the torch itself. All
of these implementations of program P are within this first
embodiment of the present invention. In the illustrated embodiment,
the wire feed speed from the magnitude signal on line 34 is
multiplied by time and directed by input line 260 to comparator
210. Thus, when the accumulated wire feed speed and time product
reaches a given level from lookup table 120 as it appears on line
200a, the logic signal on line 240 changes state and records an
action which, in this example, is a "replace tip" action. Thus, the
amount of wire fed to the torch is used to determine when the
contact tip of the torch should be replaced. In a like manner, the
logic on line 240 is also directed to action identification
register 260 by line 262. This action register indicates that the
torch should be replaced. This action is revealed by display device
260a. In practice, either line 240 or line 262 is used to determine
the action to be taken when a certain amount of wire has been
driven through the torch T. Either the tip is replaced or the torch
is replaced according to the particular action identification
signal employed. Whenever motor 30 is started, the event is
recorded in accumulator 222. A certain number of start events
indicates when the tip should be replaced. When this number is
reached, the logic on line 242 is shifted to display a replace tip
action requirement for torch T. In some instances, it is
advantageous to measure the current of motor 30. Increased motor
current is generally caused by liner friction in elongated gun G.
Liner friction is the characteristic controlled by comparator
network 214. Increase in the current of motor 30 is recorded. When
the current reaches a certain level, the logic changes on line 244.
In this instance, the accumulator 224 is merely recorded. When the
current of motor 30 reaches a certain level, as found outputted
from the lookup table for a particular type torch T, the logic on
line 244 shifts. This indicates that the liner for torch T should
be replaced. This is the message of action register 254. Thus, the
parameters of torch T monitored by monitor M can either be an
arithmetic magnitude or an accumulated level. A generic use of the
present invention for parameters is indicated by the last example.
Comparator network 216 is actuated by any parameter "n" associated
with use of torch T. The accumulated amount of parameter n is
compared to a level or value for parameter n on line 200n. This
generic parameter can be current multiplied by time to indicate the
amount of energy processed by the unique torch T. Other parameters
are within the intent and scope of the invention. The parameters
and events shown in FIG. 1 are only representative of the nature
and of the type of historical information of torch T contemplated
in practice at this time. Whenever torch T is connected to the
welding system A, the output from I/O line 154 updates all of the
accumulators to the value stored in memory 150 for the particular
torch. Memory 150 maintains a history of torch T for each of the
parameters and events in program P. When the torch has been
refurbished or a new torch is inserted with the same identification
number, memory 150 is reset by a program represented by gate 160,
as previously described.
[0035] In accordance with an aspect of the invention, monitor M
also provides life meter 300 determining the remaining anticipated
life of the torch T before it should be replaced. Life meter 300
includes register 302 that decreases from 100% to 0% by sensing the
output of one of the accumulators. As illustrated, the accumulator
220 is read by line 304, together with the limit value for the
product of wire feed speed and time. This value appears on line
306. The output of register 302 indicates the amount of life
remaining for the particular torch T. This life percentage is
displayed by device 308 or is recorded on torch T or with respect
to torch T for future use in inventory management. Program P can
take other forms; however, the computer program, as described, is
the preferred implementation of the first embodiment of the
invention.
[0036] In accordance with another aspect of torch T, it has a
separate and distinct function wherein the torch is connected to
the welding system A to provide parameters on designated line 62.
Parameters, in digital format, are selected in torch T and
transmitted by line 62 to set-up circuit 50 of controller 42. In
this separate and distinct function of torch T, the torch is a
companion to system A. Communication lead 62, runs through
elongated gun G from the front end at torch T to the rear end at
connector portion 80b. Since system A has receptacle component of
connector portion 80b, it can communicate with torch T by
designated line 62. This line communicates parameters that are used
by controller 42 to cause the desired selected welding process to
be determined by information from torch T. In accordance with this
feature of the first embodiment, torch T is constructed as shown in
FIGS. 1 and 2. An index device 320 progresses through menu 322 by
index commands on line 320a, as best shown in FIG. 2. The menu
indexes between the process to be performed and the diameter or
type of wire to be used. According to the indexed position on menu
322, a signal through line 332 corresponds to the desired process
and wire diameter and/or type and is provided from menu 322. This
data signal is communicated with a programmable set circuit or
memory 330. This set circuit or memory outputs parameters, such as
current, voltage and wire feed speed, by line 334 to designated
communication channel 62. In this way, parameters selected on the
torch are communicated to input set up circuit 50. Thus, torch T is
modified to set the welding process wire size and/or wire type by
creating parameters used by controller 42 during the welding
process. This is a separate and distinct feature associated with
torch T. In accordance with this feature, the torch has a manual
set up device or storage memory 330. This device stores the welding
parameters for a given welding process as provided by the index
position of menu 322. Line 334 communicates the selected, stored
parameters from device 330, in digital format, to line 62 for
communicating the stored parameters from the torch to controller
42. This structure sets parameters into the processing unit of
controller 42 by circuit 50. Thus, parameters stored in torch T are
used by the controller to implement a desired welding process. The
same torch has an identification code in register 100 which is
communicated with the controller through monitor M. In practice,
menu 322 and menu indexer 320 are part of the torch; however, they
can be separate from the torch.
[0037] As shown in FIG. 1, password device 140 adds to the
identification code a password for the classification or type of
torch attached to system A by connector 80a, 80b. In FIG. 3, this
torch type code is loaded into identification register 100 from a
password device 340 by transmit device 342. In a like manner, the
register 100a can be a read only memory which is loaded at the
manufacturer and read from line 60 to set decoder 130 of monitor M.
The manufacturer can also load a type code with a torch
identification code in read only memory 100a. These two
modifications of the code read/write register 100 and read only
memory 100a are illustrated in FIGS. 3 and 4. These showings are
representative of various schemes for loading the torch code and
type code into the data storage device in read only memory 100a for
communication from torch T to system A. Other minor changes in the
first embodiment of the invention shown in FIGS. 1 and 2 and the
modifications regarding communication of parameters to system A can
be made without departing from the intended spirit and scope of the
first embodiment of the invention.
[0038] The present invention involves connecting a specially
designed torch with a specially constructed welding system so that
communication occurs between the torch and system to enhance
overall efficiency and control of the welding process accomplished
by operating the welding system. In FIG. 5, a second embodiment of
the invention is illustrated. This is the preferred embodiment.
Unique torch T1 has set up devices for manually selecting weld
parameters for the welding process. A line 472 communicates
selected parameters, in digital format, to the torch T1. Line 414
communicates the torch stored parameters, in digital format, from
torch T to the controller 460 whereby the torch stored parameters
are used by the controller to implement the process. To accomplish
this objective, the rear end of the gun G1, including torch T1,
includes a connector 420 with a plug 422 matching a companion
adapter 424 on the welding system. Thus, the relationship between
torch T1 and system A1 is such that the torch can control at least
some of the parameters used in the welding system. These parameters
are manually set, at the torch, by selector device S.
[0039] Details of this second embodiment of the invention are shown
in FIG. 5. Torch T1 has handle 40 terminating in gooseneck 402 with
end nozzle 404. This torch is the front end of elongated gun or
cable G1 housing power lead 412, welding wire 412 and communication
line or channel 414. Of course, gas is communicated through gun G1
to torch T1 when shielding gas welding is being performed. To
assure that the proper torch is connected to dedicated welding
system A1, a connector 420 has an input side or plug 422 at the
rear end of gun Gland an output side or receptacle 424. This
connector is used at the intersection between gun G1 and welding
system A1. The prong or pin pattern of input 422 matches the prong
or pin pattern of output 424. Consequently, the proper torch and
system are connected. The attributes and features of novel torch T1
are, thereby, facilitated. In accordance with somewhat standard
practice, welding system A1 includes wire feeder 430 having a
supply reel 432 of welding wire W. The wire is pulled over capstan
434 by feed rolls 436 to push wire W through gun G1 to torch T1 at
a speed WFS determined by wire feed motor 438 controlled by a
microprocessor in accordance with the description of the first
embodiment illustrated in FIG. 1. Contactor 440 is standard and
includes solenoid 442 to activate contactor 440 when the trigger
(not shown) on handle 400 is depressed to close contactor 440. Of
course, a trigger lead passes through gun G1 when the torch is used
for a manual welding operation. The starter system for automatic
welding, such as used with a robot, merely closes contactor 440 by
a solenoid 442 in accordance with a start signal. When contactor
440 is closed, lead 444 which is an extension of power lead 412 is
connected to lead 446 from power source 462. Wire feeder 430 also
includes an input set circuit 450 which may or may not have a code
enabling front end, but does have an input 452 which is an
extension of communication line 414 and an output line 454, which
is a line connected to controller 460 for power source 462. Thus,
lead 454 from circuit 450 sets selected parameters or operating
features of power source 462 by inputting digital information to
controller 460. Power source 462 outputs welding current on line
446. Parameters necessary for performing a selected welding
operation between wire W and workpiece WP are stored in torch
T1.
[0040] In accordance with the second embodiment of the invention,
torch T1 includes a digital register 470 having a write line 472 to
write data information into the register from selector device or
set up device S and a read line 470a attached by connector 470b to
communication line 414. Devices can be part of the torch or a
separate unit as illustrated in FIG. 5. Buttons 480, 482 and 484
are capable of setting certain weld parameters, such as wire feed
current and voltage, for communication with controller 460 by line
414 from torch T1. Furthermore if a particular gas is to be
employed, button 486 is adjusted to select the desired gas, which
is normally CO2 and/or argon. Optionally, this button can adjust
the rate of flow of the gas, as digital data, loaded into register
or memory device 470 through write line 472. If a separate unit,
device S has output terminal 472a for information transfer to line
472. When using torch T1, set up device or selector device S is
manually adjusted by buttons 480, 482, 484 and 486 to provide the
desired parameter for the welding operation of system A.
Representative parameters are illustrated; however, a person
skilled in the art could select other parameters to be controlled
by a manual loading of register 470 on torch T1. In some
implementations of this second embodiment, device S includes a
button 490 for creating an identification code that is also written
or loaded into register 470 to be communicated to the front end of
set circuit 450. This code identifies a type of torch, but not a
specific torch. By using this type code, set circuit 450 has a
decoder front end and is enabled only upon receipt of a given type
code by way of line 414 from memory register 470. This second
embodiment of the invention allows adjustment of the desired
welding parameter at the torch, either by a unit S formed
integrally with the torch or by a separate unit S remote from the
torch. A remote unit communicates with the torch by read line 472a
during the setting operation.
[0041] The second embodiment provides unit capabilities. By storing
parameters in register 470, torch T1 will automatically load
parameters into controller 460 by merely connecting the torch to
the welding system. To enhance this capability, a toggle mechanism
474 indexes menu storage device 476 to change the parameters stored
in register or memory device 470. Device S can be a personalized
POD which is loaded by a welder to a devised parameter set. Thus,
the welder merely selects a torch and loads his parameters through
line 472. Torch T1 will always be set into a condition preferred by
the welder.
[0042] By using the invention a set of parameters can be loaded
into any torch so the torch controls the weld process. In an
alternative, the stored parameters of a torch can be changed as
desired by any weld process. Other capabilities will be apparent to
a person skilled in the welding art.
[0043] A third embodiment of the present invention is illustrated
in FIG. 6. This embodiment is somewhat similar to the second
embodiment of the invention shown in FIG. 5 and has a common
welding system and involves the same input set circuit 450.
Attachment of torch T2 activates a desired welding process with
selected parameters. To accomplish this objective, torch T2
includes a handle 500 having an outwardly projecting gooseneck 502
terminating in nozzle 504 for performing the welding operation
between wire W and workpiece WP. In accordance with this
embodiment, the rear end of the gun is connected to an interface
module 510 having a storage output section 512 and an input
identification circuit 514 to activate storage section 512 when
receiving a selected code appearing on line 516 extending through
the gun frp, torch T1. This gun is modified to communicate the
identification code by line 516 when the torch is connected to the
welding system. Thus, mere connection of the torch causes the input
section 514 to activate interface module 510 for outputting digital
data from section 512 on line 518. The data changes the parameters
in set circuit 450 which is the same set circuit as shown in FIG.
5. Interface 510 is activated, in the preferred embodiment, by
merely connecting line 516 to the module; however, in a practical
implementation, line 516 is a communication channel between torch
T2 and interface module 510 and receives digital data code from
register 520 of torch T2. This register in one implementation
merely stores a code. A code in digital format is communicated
between register 520 and input identification circuit 514. In this
implementation of the third embodiment, merely connecting torch T2
to the welding system activates module 510 because the code from
the torch is identified by input circuit 514. In summary, section
512 is activated in one example by merely connecting the torch to
the interface at the input side of the welding system. As
illustrated, section 512 is activated by section 514 reading a
specific code from the attached torch. Thus, the code for any torch
used in these examples must have a special connector 510a. In the
second example it must also have the ability to transmit a code
recognizable by decoder section 512 of interface 510.
[0044] In accordance with another aspect of this third embodiment,
storage memory register 520 is a read/write register so parameter
toggle mechanism 522 is toggled to select desired parameters, such
as the parameters shown in device S of FIG. 5. These parameters,
after being selected and stored in memory circuit 524, are written
into storage memory or register 520 from set circuit 524 by write
line 526. In accordance with another aspect, handle 500 includes a
register 530 to display the selected parameters on visual device
532. The visual data is based upon the data received from set
circuit 524 through write line 534.
[0045] The third embodiment employs an interface module 510 that
stores parameters for the welding process to be performed by the
welding system. Module 510 has a front end for activation of the
interface only when the front end receives selected input code from
torch T2 attached to the front of the module. Torch T2 has a stored
identification code in register 520 wherein the stored code matches
the selected input code of circuit 514. By communication of a
proper code from torch T2 to circuit 514, module 510 is activated.
As a further aspect torch T2 has structure on the torch which
structure includes a device for changing the stored parameters in
section 512 of module 510. In a simplified version, the code
concept is replaced by merely actuating the module by attaching the
torch.
[0046] The fourth embodiment of the present invention is
illustrated in FIG. 7. Welding torch T3 is attached to welding
system A1, as shown in FIGS. 5 and 6 and having wire feeder 430 and
a power source 462. Torch T3 comprises handle 550 with gooseneck
552 and terminal end nozzle 554 and is connected to system A1 by
gun G3 terminating in connector 560 having an input plug 562 and an
outlet receptacle 564. This same type connector is used in the
other embodiments of the present invention. The plug and receptacle
have matching prong or pin patterns to assure component matching
for proper coordination between the torch and the welding system.
In this fourth embodiment, torch T3 includes a first sensor 570 for
sensing a parameter illustrated as the welding current. Second
sensor 572 senses another parameter indicated as wire feed speed.
These two parameters are representative in nature to define the
inventive characteristics of this embodiment. The sensors are
coordinated with timer 574 so output lines 580, 582 and 584 have a
combined parameter and time signal. Multiplication circuit 586
multiplies the value of arc current on line 580 by time of the
current flow based upon reading from timer 754 as indicated by line
584. Thus, the output of circuit 586 on line 586a is the arc
current multiplied by time during which current has been flowing
through torch T3. In a like manner, multiplication circuit 588
multiplies a second parameter, indicated to be wire feed speed, by
the time on line 584 so the value on output line 588a is the
accumulated amount of wire fed through torch T3. Consequently, the
magnitude of signals on lines 586a and 588a are indicative of use
factor measurements for torch T3. These use factor measurement
signals are accumulated in accumulator 590 and are read and reset
by a memory device, shown as touch memory 592 through line 592a.
Consequently, use factor signals accumulated for the two use
related conditions are readable from storage and output device 592.
The storage and output device is interrogated by monitor unit 600
containing stored levels associated with the two use factor signals
from accumulator 590. This structure is similar to the structure
and function illustrated and discussed with respect to the
invention shown in FIG. 1. Comparator networks 602, 604 and 606
read the accumulated use factor signals in accumulator 590 by way
of storage and memory device 592 to create action commands that are
displayed on device 610, 612 and 614. In this manner, monitor unit
600 reads the use factor signals for torch T3 and displays the
actions to be taken with respect to this torch. Unit 600 can be
mounted at a remote console or at the welding operation.
Accumulator 590 maintains the history of the use criteria for torch
T3 until the accumulator is selectively reset. Reset is
accomplished by a button 620 on monitor unit 600. Upon depressing
button 620 and connecting unit 600 with accumulator 590 as
illustrated by line 600a, accumulator 590 is reset for the
particular torch T3. In this manner, the history of the torch T3 is
maintained until the torch is refurbished or otherwise
rehabilitated. Torch T3 has sensors 570, 572 to measure the level
of current and the wire feed speed. It also has a timer 574 and a
circuit 586 or 588 to combine one of more of these measurements as
a product of time to develop one or more use factor signal or
signals. Memory unit 592 accumulates the use factor signals so
monitor unit 600 can read the use factor signals selectively for a
given torch.
[0047] The fifth embodiment is schematically illustrated in FIG. 8.
Welding torch T4 has a handle 640 connected by gun G4 to welding
system A4 which includes a wire feeder 650 and a power source 660.
Power lead 652 is directed from power source 660 through wire
feeder 650 to the power lead 664 in gun G4. Power source 660 is
operated in accordance with standard practice with a standard
controller. Arc current 662 is set by circuit 664. In a like
manner, the arc voltage stage 666 is set by circuit 668. As so far
described the controller of the power source 660 and also wire
feeder 650 operates in accordance with standard practice by either
current or voltage feedback. To illustrate the inventive nature of
torch T4, power source 660 has a separate and distinct operating
system, illustrated as a system using waveform generator 670 to
process a selected waveform program from one of the stored programs
in module 672. Thus, the power source has a standard operating
procedure and a second control arrangement illustrated as a network
including a waveform generator and other related well known
components for using a waveform generator. See Fulmer U.S. Pat. No.
6,498,321 which is incorporated by reference. Network including
generator 670 is enabled by a signal in line 674. To create this
signal for shifting from standard operation to the special network
operation, novel torch T4 is employed. Handle 640 includes a stored
identification code in read/write register 680 which is
communicated by line or channel 682 through the gun G4 to the
welding system A4. The input of the welding system for line 682 is
a connector 684 having a unique plug and matching receptacle. The
same connector is illustrated as connector 654 at the input feeder
650. The unique connector 684 directs the coded digital information
on line or channel 682 to the input side of welding system A4
illustrated as decoder 690. When the proper signal is received by
decoder 690 an enable signal in line 674 activates special process
network 670. By using torch T4 attached to welding system A4, power
source 660 is converted from a standard control operation to a
higher level control protocol. Thus, gun G4 having a front end
terminating at torch T4 is connected to welding system A4. The
system automatically shifts into a high technology control
protocol. The use of the high level protocol is indicated by line
676 extending from network 670. If this protocol is deactivated, a
signal is directed to circuit 678 to shift from the high protocol
to the normal operation for power source 660.
[0048] Several embodiments are described. It is intended that
structural arrangements from any of these embodiments can be used
in the other embodiments to develop a unique arrangement of a novel
torch and a welding system coordinated with the torch to
communicate information and control the operation of the welding
system.
* * * * *