U.S. patent application number 16/714265 was filed with the patent office on 2020-06-18 for system and method for pairing welding devices.
The applicant listed for this patent is Illinois Tool Works Inc.. Invention is credited to Edward G. Beistle, Andrew D. Nelson.
Application Number | 20200189021 16/714265 |
Document ID | / |
Family ID | 49668968 |
Filed Date | 2020-06-18 |
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United States Patent
Application |
20200189021 |
Kind Code |
A1 |
Beistle; Edward G. ; et
al. |
June 18, 2020 |
System and Method for Pairing Welding Devices
Abstract
Systems and methods for pairing welding devices in a welding
system. In one method, the method includes sending a pairing
request from a first welding device to a second welding device. The
method also includes receiving, at the first welding device, a
response to the pairing request from the second welding device. The
second welding device is physically connected to the first welding
device. The pairing request or the response includes a change in
welding power, welding consumables, or any combination thereof The
method includes pairing the first welding device and the second
welding device after the first welding device receives the response
to the pairing request from the second welding device.
Inventors: |
Beistle; Edward G.;
(Appleton, WI) ; Nelson; Andrew D.; (Appleton,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Illinois Tool Works Inc. |
Glenview |
IL |
US |
|
|
Family ID: |
49668968 |
Appl. No.: |
16/714265 |
Filed: |
December 13, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13857509 |
Apr 5, 2013 |
10507542 |
|
|
16714265 |
|
|
|
|
61653887 |
May 31, 2012 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 9/24 20130101; B23K
9/1043 20130101; B23K 9/32 20130101; B23K 9/173 20130101 |
International
Class: |
B23K 9/24 20060101
B23K009/24; B23K 9/10 20060101 B23K009/10; B23K 9/32 20060101
B23K009/32; B23K 9/173 20060101 B23K009/173 |
Claims
1. A method for pairing welding devices comprising: sending a
pairing request from a first welding device to a second welding
device; receiving, at the first welding device, a response to the
pairing request from the second welding device, wherein the second
welding device is physically connected to the first welding device,
and wherein the pairing request or the response comprises a change
in welding power, welding consumables, or any combination thereof;
and pairing the first welding device and the second welding device
after the first welding device receives the response to the pairing
request from the second welding device.
2. The method of claim 1, wherein sending the pairing request from
the first welding device to the second welding device comprises
sending the pairing request using data carried by welding
power.
3. The method of claim 1, wherein sending the pairing request from
the first welding device to the second welding device comprises
sending a unique identifier of the first welding device to the
second welding device.
4. The method of claim 1, wherein the second welding device is
physically connected to the first welding device via a cable.
5. The method of claim 1, wherein the pairing request or the
response comprises a pulsed change in welding power.
6. The method of claim 1, wherein the welding consumables comprise
a shielding gas.
7. The method of claim 1, wherein the welding consumables comprise
welding wire.
8. The method of claim 1, wherein pairing the first welding device
and the second welding device comprises sending an acknowledgment
from the first welding device to the second welding device to
notify the second welding device that the response was
received.
9. The method of claim 1, comprising powering the first welding
device, wherein powering the first welding device results in the
pairing request being sent from the first welding device to the
second welding device.
10. A welding system comprising: a first welding device; and a
second welding device configured to provide welding power, welding
consumables, or any combination thereof to the first welding
device; wherein the first welding device is configured to send a
pairing request to the second welding device, receive a response to
the pairing request from the second welding device, and pair with
the second welding device after receiving the response to the
pairing request, wherein the pairing request or the response
comprises a change in welding power, welding consumables, or any
combination thereof
11. The welding system of claim 10, comprising a cable coupling the
first welding device to the second welding device.
12. The welding system of claim 11, wherein the cable is configured
to carry welding power between the first welding device and the
second welding device.
13. The welding system of claim 12, wherein the first welding
device is configured to communicate with the second welding device
using data carried by the welding power.
14. The welding system of claim 10, wherein the first welding
device is configured to initiate restoring a previous pairing with
the second welding device if the previous pairing existed within a
predetermined duration.
15. The welding system of claim 10, wherein the first welding
device is configured to send the pairing request to the second
welding device as a result of being powered on.
16. A method for pairing welding devices comprising: receiving a
pairing request from a first welding device at a second welding
device; sending, from the second welding device, a response to the
pairing request, wherein the second welding device is physically
connected to the first welding device, and wherein the pairing
request or the response comprises a change in welding power,
welding consumables, or any combination thereof; and pairing the
first welding device and the second welding device after the second
welding device sends the response to the pairing request.
17. The method of claim 16, comprising restoring a previous pairing
between the first welding device and the second welding device if
the previous pairing existed within a predetermined duration.
18. The method of claim 17, wherein the predetermined duration is
based on a duration that begins after the first welding device is
powered off
19. The method of claim 16, wherein sending the response to the
pairing request comprises sending a unique identifier of the second
welding device.
20. The method of claim 16, wherein the pairing request or the
response comprises a pulsed change in welding power.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application hereby claims priority to and the benefit
of U.S. Provisional Application No. 61/653,887, entitled "System
and Method for Pairing Welding Devices," filed May 31, 2012. This
application also is a continuation of U.S. application Ser. No.
13/857,509, entitled "System and Method for Pairing Welding
Devices," filed Apr. 5, 2013. Each of these above listed U.S.
Applications are hereby incorporated by reference in their
entireties for all purposes.
BACKGROUND
[0002] The invention relates generally to welding systems and, more
particularly, to systems and methods for pairing welding devices in
a welding system.
[0003] Welding is a process that has increasingly become utilized
in various industries and applications. Such processes may be
automated in certain contexts, although a large number of
applications continue to exist for manual welding operations. In
both cases, such welding operations rely on communication between a
variety of types of equipment (e.g., devices) to ensure that
welding operations are performed properly.
[0004] Certain welding systems may include devices that communicate
with each other using wired communication, while other welding
systems may include devices that communicate with each other using
wireless communication. Devices within the welding systems may be
paired together so that the devices know what to communicate with
within the welding system. For example, a first welding system may
include a first welding power supply paired with a first wire
feeder. As another example, a second welding system may include a
second welding power supply paired with a first remote control
device. As will be appreciated, wired and/or wireless communication
may be susceptible to cross-talk or other interference.
Accordingly, devices that attempt to pair together automatically
(e.g., without user interaction) may become incorrectly paired.
[0005] A wide range of technologies have been developed for
ensuring proper pairing of devices, particularly in the wireless
area. Many of the protocols utilized there, however, are
inappropriate to welding applications, particularly insomuch as
they are not sufficiently robust, may result in wrong pairing, and
do not address the crosstalk issues that may exist, particularly
where welding conductors are positioned near one another and to
various degrees may become inductively coupled, thereby
exacerbating the potential for crosstalk.
BRIEF DESCRIPTION
[0006] The present invention is intended to address such concerns,
particularly in the area of welding systems with their unique
problems and challenges. The proposed pairing techniques make use
of commanded or responsive changes in welding parameters to ensure
that the pairing "handshake" is proper, that is, between the proper
devices. This may both simplify the pairing process, and ensure
proper pairing, both resulting from the use of welding
application-specific parameter changes.
[0007] In one embodiment, a method for pairing welding devices
includes sending a pairing request from a first welding device to a
second welding device. The method also includes receiving, at the
first welding device, a response to the pairing request from the
second welding device. The second welding device is physically
connected to the first welding device. The pairing request or the
response includes a change in welding power, welding consumables,
or any combination thereof. The method includes pairing the first
welding device and the second welding device after the first
welding device receives the response to the pairing request from
the second welding device.
[0008] In another embodiment, a welding system includes a first
welding device and a second welding device configured to provide
welding power, welding consumables, or any combination thereof to
the first welding device. The first welding device is configured to
send a pairing request to the second welding device, receive a
response to the pairing request from the second welding device, and
pair with the second welding device after receiving the response to
the pairing request. The pairing request or the response includes a
change in welding power, welding consumables, or any combination
thereof.
[0009] In another embodiment, a method for pairing welding devices
includes receiving a pairing request from a first welding device at
a second welding device. The method also includes sending, from the
second welding device, a response to the pairing request. The
second welding device is physically connected to the first welding
device. The pairing request or the response includes a change in
welding power, welding consumables, or any combination thereof. The
method also includes pairing the first welding device and the
second welding device after the second welding device sends the
response to the pairing request.
DRAWINGS
[0010] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0011] FIG. 1 is a block diagram of an embodiment of a welding
system where a welding power unit and a welding device may be
paired together in accordance with aspects of the present
disclosure;
[0012] FIG. 2 is a block diagram of an embodiment of multiple
welding systems that may be paired together in accordance with
aspects of the present disclosure;
[0013] FIG. 3 is a flow chart of an embodiment of a method for
pairing source devices with remote devices in accordance with
aspects of the present disclosure;
[0014] FIG. 4 is a flow chart of an embodiment of a method for
pairing remote devices with source devices in accordance with
aspects of the present disclosure; and
[0015] FIG. 5 is a flow chart of an embodiment of a method for
pairing welding devices in accordance with aspects of the present
disclosure.
[0016] FIG. 6 is a flow chart of an embodiment of a method for
pairing welding devices in accordance with aspects of the present
disclosure.
DETAILED DESCRIPTION
[0017] One or more specific embodiments of the present disclosure
will be described below. These described embodiments are only
examples of the present disclosure. Additionally, in an effort to
provide a concise description of these embodiments, all features of
an actual implementation may not be described in the specification.
It should be appreciated that in the development of any such actual
implementation, as in any engineering or design project, numerous
implementation-specific decisions must be made to achieve the
developers' specific goals, such as compliance with system-related
and business-related constraints, which may vary from one
implementation to another. Moreover, it should be appreciated that
such a development effort might be complex and time consuming, but
would nevertheless be a routine undertaking of design, fabrication,
and manufacture for those of ordinary skill having the benefit of
this disclosure.
[0018] In certain embodiments, welding devices may be paired
together automatically (e.g., without user intervention). The
welding devices may be paired together using wireless and/or wired
communication over a variety of communication channels (e.g., power
line communication, RS-232, RS-485, Ethernet, Wi-Fi, Zigbee,
Bluetooth, cellular) in conjunction with a change in a signal
provided via a physical connection (e.g., welding power connection,
shielding gas connection, welding wire connection, pneumatic
connection, hydraulic connection, fiber optics connection) between
the welding devices to verify that the welding devices are
physically connected together. By verifying that the welding
devices are physically connected together, welding devices may be
accurately paired together without user intervention regardless of
whether cross-talk may exist during pairing.
[0019] As used herein, the term "pairing" means associating devices
so the devices can communicate together and so the devices can
identify one or more devices that are being communicated with. The
associating of the devices may include the devices sharing a unique
identifier with one another, and the devices storing the unique
identifiers of associated devices. Accordingly, as used herein, the
terms "paring" and "associating" are considered synonymous.
Furthermore, the terms "pair" and "associate" are synonymous, and
the terms "paired" and "associated" are synonymous. Moreover,
pairing is not limited to two devices, but encompasses an
association between any number of devices.
[0020] Turning to the figures, FIG. 1 illustrates an embodiment of
a welding system 10 (e.g., a gas metal arc welding (GMAW) system)
where a welding power unit 12 and a welding device 14 may be paired
together in accordance with aspects of the present disclosure. It
should be appreciated that, while the present discussion may focus
specifically on the GMAW system 10 illustrated in FIG. 1, the
presently disclosed pairing methods may be used in systems using
any arc welding process (e.g., FCAW, FCAW-G, GTAW, SAW, SMAW, or
similar arc welding process). Furthermore, although the present
application specifically relates to pairing welding devices
together, the pairing methods provided herein may be applied to
pairing any two devices together.
[0021] As illustrated, the welding system 10 includes the welding
power unit 12, the welding device 14 (e.g., a welding wire feeder,
remote device, pendant, remote control), a gas supply system 16,
and a welding torch 18. The welding power unit 12 generally
supplies welding power (e.g., voltage, current, etc.) to the
welding system 10 and may be coupled to the welding device 14 via a
cable bundle 20 as well as coupled to a workpiece 22 using a work
cable 24 having a clamp 26.
[0022] The cable bundle 20 may include a wired communication
channel between the welding power unit 12 and the welding device
14. For example, the welding power unit 12 may communicate with the
welding device 14 via power line communication where data is
provided (e.g., transmitted, sent, transferred, delivered) over
welding power (e.g., over the same physical electrical conductor).
As will be appreciated, the welding power unit 12 may communicate
with the welding device 14 using any suitable wired or wireless
protocol (e.g., RS-232, RS-485, Ethernet, a proprietary
communication protocol). In certain embodiments, the welding power
unit 12 and the welding device 14 may communicate using a wired
communication channel that links the welding power unit 12 and the
welding device 14 via a network (e.g., Internet, intranet). For
example, both the welding power unit 12 and the welding device 14
may be wired to the Internet using an Ethernet cable. Accordingly,
the welding power unit 12 may communicate with the welding device
14 via the Internet. In some embodiments, the welding power unit 12
and the welding device 14 may communicate (e.g., either directly,
or indirectly via a network) using a wireless communication channel
(e.g., Wi-Fi, Bluetooth, Zigbee, cellular).
[0023] As will be appreciated, the welding power unit 12 and the
welding device 14 may be paired together automatically (e.g.,
without user intervention). However, when pairing the welding power
unit 12 and the welding device 14 together cross-talk or other
interference may be present. Furthermore, the welding power unit 12
and the welding device 14 may need to have a way to verify that the
welding power unit 12 is physically coupled to the welding device
14. Accordingly, the welding power unit 12 may control a change in
welding power (e.g., change in welding voltage, change in welding
current, etc.) and/or welding consumables provided between the
welding power unit 12 and the welding device 14 so that the welding
device 14 can verify that pairing between the welding power unit 12
and the welding device 14 is occurring. For example, during pairing
of the welding power unit 12 and the welding device 14, the welding
device 14 may request verification that the welding power unit 12
is physically coupled to the welding device 14. Accordingly, the
welding power unit 12 may change welding power (e.g., current,
voltage, etc.) output from the welding power unit 12 such that the
welding device 14 can verify that the welding power unit 12 is
physically connected to the welding device 14. As another example,
during pairing of the welding power unit 12 and the welding device
14, the welding power unit 12 may request verification that the
welding device 14 is physically coupled to the welding power unit
12. Accordingly, the welding power unit 12 may send a pairing
request by changing welding power output from the welding power
unit 12 such that the welding device 14 can provide a response
indicating that the welding device 14 is physically connected to
the welding power unit 12. Furthermore, the welding power unit 12
may change a shielding gas output. In certain systems, a change in
welding wire, hydraulic fluid flow, pneumatic air flow, light or
laser transmissions, or any other change may be provided between
two devices to verify that two devices are physically connected
together. As such, the two devices may verify that they are
physically coupled together and are being correctly paired
together.
[0024] The welding power unit 12 may generally include power
conversion circuitry that receives input power from an alternating
current power source 28 (e.g., an AC power grid, an
engine/generator set, or a combination thereof), conditions the
input power, and provides DC or AC output power via the cable 20.
As such, the welding power unit 12 may power the welding device 14
that, in turn, powers the welding torch 18, in accordance with
demands of the welding system 10. The work cable 24 terminating in
the clamp 26 couples the welding power unit 12 to the workpiece 22
to close the circuit between the welding power unit 12, the
workpiece 22, and the welding torch 18. The welding power unit 12
may include circuit elements (e.g., transformers, rectifiers,
switches, and so forth) capable of converting the AC input power to
a direct current electrode positive (DCEP) output, direct current
electrode negative (DCEN) output, DC variable polarity, pulsed DC,
or a variable balance (e.g., balanced or unbalanced) AC output, as
dictated by the demands of the welding system 10.
[0025] The illustrated welding system 10 includes the gas supply
system 16 that supplies a shielding gas or shielding gas mixtures
from one or more shielding gas sources 17 to the welding torch 18.
In the depicted embodiment, the gas supply system 16 is directly
coupled to the welding power unit 12 via a gas conduit 30. The
welding power unit 12 may regulate the flow of gas from the gas
supply system 16 to the welding torch 18. In another embodiment,
the gas supply system 16 may instead be coupled to the welding
device 14, and the welding device 14 may regulate the flow of gas
from the gas supply system 16 to the welding torch 18.
[0026] A shielding gas, as used herein, may refer to any gas or
mixture of gases that may be provided to the arc and/or weld pool
in order to provide a particular local atmosphere (e.g., to shield
the arc, improve arc stability, limit the formation of metal
oxides, improve wetting of the metal surfaces, alter the chemistry
of the weld deposit, and so forth). In certain embodiments, the
shielding gas flow may be a shielding gas or shielding gas mixture
(e.g., argon (Ar), helium (He), carbon dioxide (CO2), oxygen (O2),
nitrogen (N2), similar suitable shielding gases, or any mixtures
thereof). For example, a shielding gas flow (e.g., delivered via
conduit 30) may include Ar, Ar/CO2 mixtures, Ar/CO2/O2 mixtures,
Ar/He mixtures, and so forth.
[0027] In the illustrated embodiment, the welding device 14 is
coupled to the welding torch 18 via a cable bundle 32 in order to
supply consumables (e.g., shielding gas, welding wire) and welding
power to the welding torch 18 during operation of the welding
system 10. In another embodiment, the cable bundle 32 may only
provide welding power to the welding torch 18. During operation,
the welding torch 18 may be brought near the workpiece 22 so that
an arc 34 may be formed between the consumable welding electrode
(i.e., the welding wire exiting a contact tip of the welding torch
18) and the workpiece 22.
[0028] FIG. 2 is a block diagram of an embodiment of multiple
welding systems 36 that may be paired together in accordance with
aspects of the present disclosure. As illustrated, the multiple
welding systems 36 may include multiple source devices (e.g.,
welding power units 12) such as a welding device (S 1) 38, a
welding device (S 2) 40, a welding device (S 3) 42, a welding
device (S 4) 44, and a welding device (S 5) 46. A "source device"
as used herein generally refers to a device that provides a
response to a remote device via a physical connection between the
source device and the remote device. The response is a
unidirectional output from the source device of something provided
by the source device and is not standard communication (e.g., it is
not something that is used for continuous communication). For
example, the source device may provide a pulse or change in a high
power output (e.g., welding power), a gas flow, a fluid flow, a
heat provided, a light emitted, a sound, and so forth. The source
device may be paired with the remote device to exchange data with
the remote device.
[0029] Furthermore, the multiple welding systems 36 may include
multiple remote devices (e.g., welding devices 14) such as a
welding device (RD 1) 48, a welding device (RD 2) 50, a welding
device (RD 3) 52, a welding device (RD 4) 54, and a welding device
(RD 5) 56. A "remote device" as used herein generally refers to a
device that receives a response from the source device via a
physical connection between the remote device and the source
device. The response is a unidirectional output from the source
device of something provided by the source device and is not
standard communication. For example, the remote device may receive
a pulse or change in a high power output (e.g., welding power), a
gas flow, a fluid flow, a heat provided, a light emitted, a sound,
and so forth. The remote device may be paired with the source
device to exchange data with the source device.
[0030] As illustrated, each of the source devices may be physically
coupled to one of the remote devices. For example, S 1 38 may be
physically coupled to RD 3 52 via a physical connection 58. In
addition, S 2 40 may be physically coupled to RD 4 54 via a
physical connection 60. Furthermore, S 3 42 may be physically
coupled to RD 1 48 via a physical connection 62. Likewise, S 4 44
may be physically coupled to RD 5 56 via a physical connection 64.
Moreover, S 5 46 may be physically coupled to RD 2 50 via a
physical connection 66. Although the source devices are physically
coupled to the remote devices, standard communication between the
source devices and the remote devices may not occur using the
physical connections. However, the physical connections are needed
during the pairing process to verify that a source device is
physically coupled to a remote device.
[0031] In certain embodiments, the physical connections 58, 60, 62,
64, and 66 may include cables where welding power (e.g., voltage,
current, etc.) is provided from the source device to the remote
device. Furthermore, data may be provided between the source
devices and the remote devices by modulating the data over the
welding power (e.g., power line communication). As previously
explained, cross-talk may exist between data provided over
different physical connections 58, 60, 62, 64, and 66. Accordingly,
as source devices and remote devices may attempt to automatically
pair together using the data over the welding power, data may be
incorrectly provided to an undesired source device and/or remote
device. As such, the welding power may be used to verify that a
source device is physically coupled to a remote device. For
example, a predetermined change (e.g., a pulsed change) in welding
power may be used to signify that a particular source device is
coupled to a particular remote device, as explained in greater
detail in FIGS. 3 and 4.
[0032] FIG. 3 is a flow chart of an embodiment of a method 68 for
pairing source devices with remote devices in accordance with
aspects of the present disclosure. At block 70, a source device
determines that it is unassociated (e.g., not paired) with a remote
device. At block 72, the source device determines whether it is
unassociated because of lost communication between the source
device and a remote device. If the source device determines that it
is unassociated with a remote device because of lost communication,
the source device is re-associated (e.g., re-paired) with the
remote device, per block 74. In certain embodiments, the source
device may have a predetermined time period (e.g., approximately 10
seconds) after lost communication to re-associate with the remote
device. In some embodiments, the predetermined time period may be
based on a duration after the source device is powered on. The
source device determines whether a timeout (e.g., a time period
that elapses without communication) occurs between the source
device and the remote device (block 76). If a timeout occurs, the
source device determines that it is unassociated with the remote
device (block 70). However, if a timeout does not occur, the source
device remains associated with the remote device and continues to
determine whether a timeout occurs (block 76).
[0033] Returning to block 72 , if the source device determines that
it is not unassociated with a remote device because of lost
communication, the source device may determine whether a petition
for association has been received by a remote device (block 78). A
petition for association is sent by a remote device when the remote
device seeks to be paired with a source device. If a petition for
association has not been received, the source device returns to
block 70. However, if a petition for association has been received,
the source device arbitrates (e.g., decides) which remote device
will get control of the association process and broadcast the
identity of the remote device that will get control (e.g., the
arbitration device) (block 80). At block 82, the source device
determines whether a timeout (e.g., a time period that elapses
without a new arbitration device identity being broadcast) occurs
after the identity of the arbitration device has been broadcast. If
a timeout does not occur (e.g., a new arbitration device identity
is broadcast), the source device returns to block 80. However, if a
timeout occurs (e.g., there is not a new arbitration device
identity broadcast), the arbitration device is granted control by
the source device (block 84).
[0034] After the arbitration device is granted control, the source
device determines whether a timeout occurs (e.g., too much time
elapses before an identity request is received) (block 86). If a
timeout occurs, the source device returns to block 70. However, if
a timeout does not occur, the source device determines whether it
has been released by the arbitration device (e.g., the arbitration
device has emptied its list and an identity request of the source
device was not received) (block 88). If the source device has been
released by the arbitration device, the source device returns to
block 70. If the source device has not been released by the
arbitration device, the source device determines whether an
identity request (e.g., a request for the source device to output
an identifications signal over the physical connection) has been
received (block 90). If an identity request has not been received,
the source device returns to block 86.
[0035] On the other hand, if an identity request has been received,
the source device broadcasts an identification signal (e.g., a
change in welding power output, shielding gas flow, welding wire
flow, hydraulic flow, pneumatic flow, light transmissions) (block
92). At block 94, the source device determines whether a timeout
has occurred since the identification signal was sent. If a timeout
has occurred, the source device returns to block 70. However, if a
timeout has not occurred, the source device determines whether a
reject message is received from a remote device (e.g., rejecting an
association with the source device) (block 96). If a reject message
is received, the source device returns to block 70. However, if a
reject message is not received, the source device determines
whether a locking signal has been received (block 98). If a locking
signal has not been received, the source device returns to block
94. However, if a locking signal has been received, the source
device is associated with the remote device (block 74).
Accordingly, the source device is associated (e.g., paired) with
the remote device using a response (e.g., identification signal)
provided over a physical connection to verify that the devices are
physically connected together. The physical connection ensures that
any present cross-talk does not interfere with the pairing of the
source device and the remote device. Once paired, the source device
and the remote device may communicate together knowing that they
are the devices that are physically coupled together.
[0036] FIG. 4 is a flow chart of an embodiment of a method 100 for
pairing remote devices with source devices in accordance with
aspects of the present disclosure. At block 102, the remote device
is initialized (e.g., powered on, reset). After being initialized,
the remote device determines whether it is ready to associate with
a source device (block 104). If the remote device determines that
it is not ready to associate with a source device, the remote
device returns to block 102. However, if the remote device
determines that it is ready to associate with a source device, the
remote device determines whether it has been previously associated
with a source device (block 106).
[0037] If the remote device has been previously associated with a
source device, the remote device re-associates with the source
device (block 108). In certain embodiments, the remote device may
re-associate (e.g., recover) a previous association if the previous
association existed within a predetermined duration (e.g., such as
a duration that begins after the remote device is powered on).
After re-associating, the remote device determines whether a
timeout (e.g., a time period that elapses without communication)
occurs between the remote device and the source device (block 110).
If a timeout has not occurred, the remote device returns to block
110. If a timeout occurs, the remote device may have lost
communication with the source device (block 112). Per block 114, if
a timeout occurs after communication is lost, the remote device
returns to block 102. If a timeout does not occur, the remote
device determines whether communication has been restored (block
116). If communication between the remote device and the source
device has been restored, the remote device returns to block 108.
If communication between the remote device and the source device is
not restored, the remote device returns to block 112.
[0038] Returning to block 106, if the remote device has not been
previously associated with a source device, the remote device
provides a petition for arbitration (e.g., a request to be paired)
to the source devices (block 118). At block 120, the remote device
determines whether a grant to be the arbitration device has been
received from a source device. The arbitration device is an
unassociated device that is used to control the order of identity
requests sent to source devices. If a grant to be the arbitration
device has been received by the remote device, a source device
grants control to the remote device (block 122). The remote device
then determines whether a timeout has occurred since it was granted
control (block 124). If a timeout has not occurred, the remote
device determines whether a grant for a higher ranking (e.g.,
higher identification number, lower identification number, etc.)
remote device has been received (block 126). If the remote device
has received a grant for a higher ranking device, the remote device
returns to block 118. If however, the remote device has not
received a grant for a higher ranking device, the remote device
returns to block 124.
[0039] At block 124, if a timeout has occurred (e.g., there is not
a higher ranking device), the remote device takes control (e.g.,
gets the floor) and begins to request that source devices identify
themselves by cycling through a list of source devices that the
remote device has received communication from (block 128). The
remote device goes sequentially through each source device in its
list and sends a request to the source device for an identity
response. At block 130, the remote device determines whether it has
received a response from a source device (e.g., a source device has
been identified) physically connected to the remote device (e.g.,
whether the remote device has received an identity response from
the requested source device). If the remote device has not
identified a physically connected source device, the remote device
determines whether its list of source devices is empty (block 132).
If the remote device does not have an empty list, the remote device
returns to block 128. On the other hand, if the remote device has
an empty list, the remote device returns to block 118.
[0040] Returning to block 130, if the remote device has identified
the source device that it is coupled to (e.g., received an identity
response such as a change in an output from the source device), the
remote device sends a locking signal to the source device (block
134). As illustrated, block 134 may also be reached by the remote
device identifying the source device that it is coupled to per
block 136. At block 138, the remote device determines whether a
timeout has occurred (e.g., a time period has elapsed). If a
timeout has occurred, the remote device returns to block 102.
However, if a timeout has not occurred, the remote device
determines whether the source device is ready to be associated with
the remote device (e.g., whether the source device has provided an
acknowledgment of the locking signal) (block 140). If the source
device has not acknowledged receipt of the locking signal, the
remote device returns to block 138. On the other hand, if the
source device has acknowledged receipt of the locking signal, the
remote device broadcasts a release signal to release other source
devices (block 141) and is associated with the source device per
block 108. Accordingly, the remote device may be associated (e.g.,
paired) with the source device to which it is physically
connected.
[0041] FIG. 5 is a flow chart of an embodiment of a method 142 for
pairing welding devices in accordance with aspects of the present
disclosure. In the present embodiment, a pairing request (e.g.,
request for association) is sent from a first device (e.g., first
welding device) to a second device (e.g., second welding device)
(block 144). The pairing request may be sent automatically (e.g.,
without user intervention), such as when the first device is
powered on or restarted. In certain embodiments, the pairing
request may be sent from the first device to the second device via
data carried by welding power (e.g., power line communication). In
other embodiments, the pairing request may be sent using any
suitable wired or wireless communication. Furthermore, in some
embodiments the pairing request may include a unique identifier
that may be used by the second device to identify the first device.
The first device receives a response to the pairing request (block
146).
[0042] As previously described, the second device is physically
connected to the first device and the response to the pairing
request includes a change (e.g., a pulsed change) in something
physically carried by the physical connection (e.g., welding power,
welding consumables such as shielding gas flow and welding wire,
air flow, gas flow, fluid flow, light transmissions, heat
transmissions, sound). As will be appreciated, the physical
connection may be a cable (e.g., fiber optic, electrical, welding),
wire, electrical conductor, hose, tube, and so forth. After
receiving the response to the pairing request from the second
device, the first device and the second device are paired together
(block 148). As may be appreciated, in some embodiments, the
pairing request itself may be a change in something physically
carried by the physical connection, while the response may be data
carried by welding power and/or both the pairing request and the
response may be a change in one or more things physically carried
by the physical connection. In certain embodiments, before the
first and second devices are paired together, the first device may
send an acknowledgment to the second device that the response was
received. Using such a method, the first and second devices may be
paired together even if cross-talk exists in the environment where
the first and second devices are located.
[0043] FIG. 6 is a flow chart of an embodiment of a method 150 for
pairing welding devices in accordance with aspects of the present
disclosure. In the present embodiment, a pairing request (e.g.,
request for association) is sent from a first device (e.g., first
welding device) to a second device (e.g., second welding device)
(block 152). The pairing request may be sent automatically (e.g.,
without user intervention), such as when the first device is
powered on or restarted. A response to the pairing request is
received, at the first welding device from the second welding
device (block 154). For example, the second welding device is
physically connected to the first welding device, and the response
includes a predetermined change in provision of voltage or current
of a welding power output, or welding consumables, or any
combination thereof. In the example of method 150, the
predetermined change corresponds to an identification signal that
identifies the second welding device through the physical
connection between the first welding device and the second welding
device. In certain embodiments, the pairing request may be sent
from the first device to the second device via data carried by
welding power (e.g., power line communication). In other
embodiments, the pairing request may be sent using any suitable
wired or wireless communication. A determination is made at the
first welding device that the first welding device is physically
connected to the second welding device via the physical connection
(block 156). In examples, the determination is based on the
predetermined change in the voltage or current of the welding power
output, or the welding consumables, or any combination thereof,
that identifies the second welding device through the physical
connection. Furthermore, in some embodiments, the first welding
device and the second welding devices are paired (block 158) after
the first welding device receives the response to the pairing
request from the second welding device.
[0044] Although the embodiments described herein have focused on
pairing a source device to a remote device, in certain embodiments
a source device may be paired with multiple remote devices.
Furthermore in some embodiments, a remote device may be paired with
multiple source devices. Likewise, a pairing combination may be
made between any source device and any remote device. As will be
appreciated, in certain embodiments, a remote device may also be a
source device. Moreover, in some embodiments, a source device may
also be a remote device.
[0045] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
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