阅读说明：本技术 用于焊接机的无线遥控通信的方法和装置 (Method and apparatus for wireless remote control communication for welders ) 是由 约翰·勒克 斯蒂芬·P.·弗克尔 于 2007-09-20 设计创作，主要内容包括：一种从远距离位置将控制信号与焊接电源(12)通信的方法和装置,包括由设置在远离该焊接电源的无线遥控器传输的控制信号操作的焊接系统。响应于传输到接收器(36)的无线指令信号,该焊接系统中的多个焊接参数被设置和调节,该接收器通过连接口(37)连接到该焊接电源,并进一步地连接到所述焊接电源中的控制器。在这方面,操作者能从远距离位置很快地且有效地控制焊接系统,除执行预定任务必需的电缆外,其它不需要。(A method and apparatus for communicating control signals to a welding power supply (12) from a remote location includes a welding system operated by control signals transmitted by a wireless remote control located remotely from the welding power supply. A plurality of welding parameters in the welding system are set and adjusted in response to wireless command signals transmitted to a receiver (36) connected to the welding power source through a connection port (37) and further connected to a controller in the welding power source. In this regard, the operator can quickly and efficiently control the welding system from a remote location, without the need for cables other than those necessary to perform the intended task.)

1. A wireless remote control kit for retrofitting a welding-type device, comprising:

a wireless control device configured to transmit command signals to control a plurality of welding operating parameters in a welding-type device adapted to generate welding-type power;

a wireless receiver remote from the wireless control device and configured to receive the command signal and transmit the command signal to the welding-type device; and is

Wherein the wireless receiver for receiving the command signal for controlling a welding-type operation is configured to be operably connected to a controller disposed in a power supply of the welding-type device by connecting to an existing control cable connection port located on an exterior of the power supply without a cable such that when the wireless receiver is engaged with the existing control cable connection port located on the exterior of the power supply, there is no cable between the wireless receiver and the power supply and the welding-type operation is performed by the welding system based at least in part on the welding operating parameters;

wherein the existing control cable connection port is configured to be connected with a control cable connected to a wired control device when the wireless receiver is not engaged with the existing control cable connection port, and the wireless receiver is engaged with the existing control cable connection port instead of the control cable when the control cable is not engaged with the existing control cable connection port.

2. The wireless remote control kit for modifying welding-type equipment as recited in claim 1, wherein the existing control cable connection port is a 14-pin connector.

3. The wireless remote control kit for retrofitting a welding-type apparatus of claim 1 wherein said wireless remote control is further configured as one of a hand grip control, a foot pedal control, and a fingertip control.

4. The wireless remote control kit for modifying a welding-type device of claim 1, wherein the plurality of welding parameters comprises current, voltage, inductance, and pulse commands.

5. The wireless remote control kit for retrofitting a welding-type apparatus of claim 1 wherein the wireless control device communicates with the wireless receiver via one of Radio Control (RC), Radio Frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, wireless transmission technology, bluetooth, infrared data transmission, multi-channel multi-drop service, local multi-drop service, WiMAX, 802.11Wi-Fi, infrared, ultra high frequency, uhf, vhf, and radar intelligence.

6. A method for adapting an existing welding-type system for use with a wireless remote control, comprising the steps of:

connecting a wireless receiver for receiving command signals for controlling a welding-type operation to a welding-type power source without a cable through an existing control cable connection port located on an exterior of the welding-type power source, such that when the wireless receiver is engaged with the existing control cable connection port located on the exterior of the welding-type power source, there is no cable between the wireless receiver and the welding-type power source, and the welding-type operation is performed by the welding system based at least in part on welding operating parameters;

wherein the existing control cable connection port is configured to connect with a control cable connected to a wired control device when the wireless receiver is not engaged with the existing control cable connection port, and to engage with the existing control cable connection port in place of the control cable when the control cable is not engaged with the existing control cable connection port;

wirelessly transmitting the command signal indicative of a desired operating parameter of the welding-type system from a wireless remote control;

receiving the command signal remotely by the wireless receiver; and

controlling the welding-type system based on data contained in the received wirelessly transmitted command signal.

7. The method of claim 6, wherein the desired operating parameter comprises at least one of current, voltage, inductance, pulse command, voltage feedback, current feedback, and output activation.

8. The method of claim 6, wherein the step of wirelessly transmitting signals further comprises the step of wirelessly transmitting signals by one of Radio Control (RC), Radio Frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, wireless transmission technology, bluetooth, infrared data transmission, multi-channel multi-drop service, local multi-drop service, WiMAX, 802.11Wi-Fi, infrared, uhf, vhf, and radar intelligence maps.

9. The method of claim 6, wherein the step of connecting the wireless receiver to the welding-type power source through an existing control cable connection port further comprises the step of connecting the wireless receiver through a 14-pin connector.

10. A wireless remote control kit for retrofitting a welding-type device, comprising:

a wireless receiver configured to receive command signals and to transmit the received command signals to the welding-type device to control a plurality of welding operating parameters in the welding-type device;

wherein the wireless receiver for receiving the command signal for controlling a welding-type operation is configured to be operably connected to a controller disposed in a power supply of the welding-type device by connecting to an existing control-cable connection port located on an exterior of the power supply without a cable, such that when the wireless receiver is engaged with the existing control-cable connection port located on the exterior of the power supply, there is no cable between the wireless receiver and the power supply, and configured to receive the command signal for controlling a welding-type operation performed by the welding system based at least in part on the welding-operation parameters;

wherein the existing control cable connection port is configured to be connected with a control cable connected to a wired control device when the wireless receiver is not engaged with the existing control cable connection port, and to be engaged with the existing control cable connection port instead of the control cable when the control cable is not engaged with the existing control cable connection port.

11. The wireless remote control kit for modifying welding-type equipment of claim 10 wherein the existing control cable connection port is a 14-pin connector.

12. A welding-type system, comprising:

a welding-type power source having a controller to regulate a welding operation;

a wireless remote control configured to remotely transmit command signals for controlling at least one of a plurality of welding operating parameters in the welding-type system;

a wireless receiver coupled to the controller remote from the wireless remote control, the wireless receiver configured to receive the command signal and allow the controller to adjust at least one of a plurality of welding operating parameters in response to the command signal;

wherein the wireless receiver for receiving the command signal for controlling a welding-type operation is configured to engage, without a cable, an existing welding-type control cable connection port located on an exterior of the welding-type power source such that when the wireless receiver engages the existing welding-type control cable connection port located on the exterior of the welding-type power source, there is no cable between the wireless receiver and the welding-type power source, and the welding-type operation is performed by the welding system based at least in part on the welding operating parameters.

13. The welding-type system of claim 12 wherein the existing welding-type control cable connection port is a 14-pin connector.

14. The welding-type system of claim 12 wherein the plurality of welding parameters comprises current, voltage, inductance, and pulse commands.

15. The welding-type system of claim 12, wherein the wireless receiver is operatively connected to the welding-type power source and the controller to communicate signals therebetween.

16. The welding-type system of claim 12, wherein the wireless remote control communicates with the wireless receiver via one of Radio Control (RC), Radio Frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, wireless transmission technology, bluetooth, infrared data transmission, multi-channel multi-drop service, local multi-drop service, WiMAX, 802.11Wi-Fi, infrared, ultra high frequency, uhf, vhf, and radar intelligence maps.

17. The welding-type system of claim 12 wherein the wireless remote control is configured as one of a hand grip control, a foot pedal control, and a fingertip control.

18. A wireless remote control kit, comprising:

a wireless control device configured to transmit command signals to control a plurality of welding operating parameters in a welding-type device adapted to generate a welding-type power; and

a wireless receiver remote from the wireless control device and configured to receive the command signal and transmit the command signal to the welding-type device;

wherein the wireless receiver for receiving the command signal for controlling a welding-type operation is configured to be operably connected, without a cable, to a controller disposed in a welding-type power source of the welding-type device by connecting with an existing welding-type control cable connection port located on an exterior of the welding-type power source such that there is no cable between the wireless receiver and the welding-type power source when the wireless receiver is engaged with the existing welding-type control cable connection port located on the exterior of the welding-type power source, and wherein the welding-type operation is performed by the welding system based at least in part on the welding operating parameters.

19. The wireless remote control kit of claim 18, wherein the existing welding-type control cable connection port is a 14-pin connector.

20. The wireless remote control kit of claim 18, wherein the wireless control device is configured as one of a hand grip control, a foot pedal control, and a fingertip control.

21. The wireless remote control kit of claim 18, wherein the plurality of welding parameters comprise current, voltage, inductance, and pulse commands.

22. The wireless remote control kit of claim 18, wherein the wireless control device communicates with the wireless receiver via one of Radio Control (RC), Radio Frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, wireless transmission technology, bluetooth, infrared data transmission, multi-channel multicast service, local multicast service, WiMAX, 802.11Wi-Fi, infrared, uhf, vhf, and radar intelligence maps.

23. A method, comprising:

connecting a wireless receiver that receives command signals for controlling a welding-type operation to a welding-type power source without a cable through an existing welding-type control cable connection port located on an exterior of the welding-type power source, such that when the wireless receiver is engaged with the existing welding-type control cable connection port located on the exterior of the welding-type power source, there is no cable between the wireless receiver and the welding-type power source, and the welding-type operation is performed by the welding system based at least in part on welding operating parameters;

wirelessly transmitting the command signal from a wireless remote control, wherein the command signal is indicative of a desired operating parameter of the welding-type power source;

receiving the command signal remotely by the wireless receiver; and

controlling the welding-type power source based on data contained in the received wirelessly transmitted command signal.

24. The method of claim 23, wherein the desired operating parameter comprises at least one of current, voltage, inductance, pulse command, voltage feedback, current feedback, and output activation.

25. The method of claim 23, wherein the step of wirelessly transmitting signals comprises the step of wirelessly transmitting signals by one of Radio Control (RC), Radio Frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, wireless transmission technology, bluetooth, infrared data transmission, multi-channel multicast service, local multicast service, WiMAX, 802.11Wi-Fi, infrared, uhf, vhf, and radar intelligence maps.

26. The method of claim 23, wherein the step of connecting the wireless receiver to a welding-type power source through an existing welding-type control cable connection port comprises the step of connecting the wireless receiver through a 14-pin connector.

27. A wireless remote control kit, comprising:

a wireless receiver configured to receive a command signal and transmit the command signal to the welding-type device to control a plurality of welding-type operating parameters in the welding-type device;

wherein the wireless receiver for receiving the command signal for controlling a welding-type operation is configured to be operably connected, without a cable, to a controller disposed in a welding-type power source of the welding-type device by connecting with an existing welding-type control cable connection port located on an exterior of the welding-type power source such that when the wireless receiver is engaged with the existing welding-type control cable connection port located on the exterior of the welding-type power source, there is no cable between the wireless receiver and the welding-type power source, and the welding-type operation is performed by the welding system based at least in part on the welding-type operating parameters.

28. The wireless remote control kit of claim 27, wherein the existing welding-type control cable connection port is a 14-pin connector.

Technical Field

The present invention relates generally to welders, and more particularly to a method and apparatus for communicating control signals to a welding power source from a remote location. In particular, the present invention relates to welding systems that control operation via control signals transmitted by a wireless remote control. In response to wireless command signals received by the welding power supply, a plurality of welding parameters in the welding system are set and adjusted. In this regard, the operator can quickly and efficiently control the welding system from a remote location, without the need for cables other than those necessary for welding.

Background

Welding and cutting are essential operations in many different fields of manufacturing and construction in today's economy. The versatility and efficiency of the welding and cutting system is critical and allows for the efficient completion of many complex and dynamic welding operations. In many welding and cutting operations performed by operators, welding-type systems are adjustable during the process to accommodate different welding-type operations. When such adjustments are needed, the welding parameters of the welding-type system need to be set appropriately for each different welding-type process. In each process, the parameters need to be set and adjusted before and during the welding-phase type process. In many cases, the welding-type process occurs at a distance from the actual welding machine/power source. Thus, the operator needs to walk back to the machine to make any needed adjustments. To overcome this problem, some welding-type systems have begun to incorporate some form of remote control. In many existing systems, power and signals between the operator's location and the welding-type power source location are transmitted over cables. These cables provide a simple and reliable method for communication and control of different welding parameters.

While this configuration has advantages, it also has disadvantages associated with communication and control of the welding-type system. One disadvantage of such cable-based control is that the communication cable is generally fragile relative to the welding cable which carries high currents at high voltages. Welding-type systems are often used in unusual situations where the system is periodically relocated or surrounded by other moving heavy equipment operating in the same area. Thus, the remote communication cable may be damaged by crushing or snagging on contact with the surrounding machinery and/or wiring. If the internal power leads become shorter than the signal leads connected to sensitive signal level circuitry, this can result in damage to the welding-type power source and significantly reduced productivity.

Additional problems also arise with communication cables for remote control of welding equipment. One of the high frequency electrical noise that is imparted to welding-type systems is due to the presence of the environment surrounded by the communication cable. The communication cable provides a conduit for noise to enter the power supply and controller of the welding-type system. This noise and interference must be filtered out so as not to negatively affect the performance of the system.

Because of the problems associated with the communication cables of remote welding-type systems, many attempts have been made to attempt to change the communication scheme in new systems. Various types of remote control devices have been introduced and facilitate operator manipulation of welding-type processes by a means other than just a standard communications cable. However, redesigned systems may be designed to include such wireless remote control devices, but the problem of not being able to implement wireless remote control in current welding systems still remains. Therefore, there is a need for an improved existing system for providing an existing welder with a remote device that can control the welding operation in a manner that is practical and efficient for the operator.

The incorporation of a remote control device into an existing welding system and the ability to wirelessly control multiple welding operations is a feature that will greatly enhance the productivity of existing welding systems. The use of a wireless remote control, which eliminates the communication cable, would overcome many of the associated high frequency electrical noise as described above. Wireless remote control also provides many advantages and convenience to the operator, such as reducing the inconvenience of additional cables. The elimination of the communication cable will also eliminate damage due to sparks, high melting metals and heavy objects falling onto the cable and may improve the portability of the welding system. The elimination of additional cables also provides convenience in using the welding system in enclosed areas.

Disclosure of Invention

The present invention overcomes the above-identified deficiencies and adds the above advantages to a welding-type system by providing a system that enables wireless control of multiple welding parameters from a remote location. The welding-type system includes a welding power source having a controller, a welding torch, a wireless remote control capable of controlling a plurality of parameters in the welding system, and a receiver.

In accordance with one aspect of the present invention, therefore, a welding-type system is disclosed, comprising,

a power source having a controller to regulate a welding operation; a welding gun connected to the power source; a wireless remote control configured to remotely transmit a signal for controlling at least one of a plurality of welding parameters in the welding system; a wireless receiver connected to the controller remote from the wireless remote control, the receiver configured to receive the signal and allow the controller to adjust at least one of a plurality of welding parameters in response to the signal; wherein the wireless receiver is further configured to engage an existing connection port located on the exterior of the power source, the connection port configured to engage both a control cable to which the line control device is connected and the receiver in place of the control cable.

In accordance with another aspect of the present invention, a wireless remote control kit for retrofitting a welding-type device is provided. The wireless remote control kit includes a wireless control device configured to transmit signals to control a plurality of welding parameters of a welding-type device adapted to generate a welding-type power. The wireless remote control kit further includes a receiver remote from the wireless control device and configured to receive and transmit signals to the welding-type device. The receiver is operatively connected to a controller disposed in the power source of the welding-type device.

In accordance with a further aspect of the present invention, a method of adapting an existing welding-type system for use with a wireless remote control is disclosed. The method includes the steps of connecting a receiver to a welding-type power source via an existing control cable connection port, wirelessly transmitting a signal from a wireless remote control indicative of desired operating parameters of the welding-type system, remotely receiving the signal via the receiver, and controlling the welding-type system in accordance with data contained in the received wirelessly transmitted signal.

Many other features and advantages of the present invention will be apparent from the following detailed description and the accompanying drawings.

Drawings

The drawings illustrate a preferred embodiment which is presently used to practice the invention.

In the drawings:

FIG. 1 is a perspective view of a welding-type system and a remote communication system for controlling a welding-type device in accordance with the present invention;

fig. 2 is a perspective view of the welding-type system of fig. 1 and a detailed view of a connection port thereon.

Detailed Description

FIG. 1 illustrates a welding-type system capable of performing various types of operations. The welding-type system 10 is merely representative of a variety of welding-type machines having different sizes, characteristics, and ratings. The welding-type systems contemplated herein may be configured to perform not only standard welding-type operations, such as Tungsten Inert Gas (TIG), Metal Inert Gas (MIG), and/or hand arc (stikwelding), but also various cutting operations that are closely related to various welding processes, such as plasma cutting. In the exemplary embodiment of FIG. 1, the welding-type system shown is preferably a Tungsten Inert Gas (TIG) welding system, but one skilled in the art will readily appreciate that any related welding or cutting system including those listed above may be included. TIG welding system 10 includes a power source 12 that determines (conditions) raw power and generates a power signal suitable for a welding application. Power source 12 includes a processor/controller 13 that receives operational feedback and monitors the operation of TIG welding system 10. The welding gun 16 is connected to the power source 12 by a cable 18. The cable 18 provides the required power and compressed air or gas to the torch 16. The gun 16 includes a handle portion 29 or gun body having a trigger 31 thereon for actuating the gun and a working tip 32 extending therefrom.

Also connected to the power source 12 is a work piece holder 20 which is designed to be connected to a work piece (not shown) to be welded and to provide a return path. Connecting the workpiece holder 20 to the power source 12 is an electrical cable 22, the electrical cable 22 being designed to provide a return path for welding current from the welding gun 16 through the workpiece and the workpiece holder 20. Extending from the rear 23 of the power source 12 is a power cable 24 having a plug 26 for connecting the power source 12 to a portable power supply (not shown) or a transmission line power jack (not shown). Also connected to the power source is a gas source 33 configured to supply a gas flow to the torch 16.

The wireless remote control 50 and receiver 36 are included in the welding-type system 10 and are configured to set and adjust operating parameters thereof in view of wireless operation of the welding-type system 10 from a location remote from the power source 12. During welding-type operations, the wireless remote control 50 is located remotely from the welding-type power supply 12 and communicates with the receiver 36. The receiver 36 is operatively connected to the controller 13 and the welding-type power source 12, and is configured to receive and transmit wireless signals from the control device 50 to the controller 13 to process the received wireless data. In this manner, the wireless remote control 50 controls the operation of the welding-type system 10 and sets or adjusts the various welding-type parameters described above.

As shown in fig. 1, receiver 36 is specifically configured to interconnect with an existing connection port 37 of welding-type system 10. In addition to interconnecting with receiver 36, connection port 37 (shown in FIG. 2) is also configured to engage a standard control cable commonly used in welding systems. When receiver 36 is configured to engage connection port 37, previous welding-type systems that were not controllable via a wireless remote control device may be readily modified (i.e., retrofitted) to incorporate receiver 36 and wireless remote control 50 of the present invention. In one embodiment of the present invention, the receiver 36 may be configured to connect to the welding-type power source 12 through an existing 14-pin connector 37 located on the front panel 42 of the power source 12. Preferably, receiver 36 is operable with an ac or dc power source and spans different control voltages, at least ranging from 5 volts to 24 volts. A typical control circuit with a wide voltage window is preferred to accomplish this function.

A variety of communication means may be used to transmit signals from wireless remote control 50 to receiver 36. In a preferred embodiment, radio control signals are used. However, other communication means may include, but are not limited to, Radio Frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, wireless transmission technology, Bluetooth, infrared data transmission (IrDA), multi-channel multipoint distribution service, local multipoint distribution service, WiMAX, 802.11Wi-Fi, infrared, Ultra High Frequency (UHF), Very High Frequency (VHF), and Radar Intelligence Map (RIM). It can be seen that the mode of communication selected depends on the needs of the welding-type process and the environment in which the process is located.

As shown in fig. 1, the wireless remote controller 50 is conceivable to be controlled by foot pedals, hand-held controls or finger-tip controls. However, these specific embodiments are not meant to limit the form of the wireless remote control 50 used in the present invention. The wireless remote control 50, in the form of a foot pedal control, a finger tip control, or a hand held control, may include switches (not shown) or other similar devices thereon that allow an operator to easily adjust and control one or more welding parameters in the welding-type system 10. These controllable welding parameters may include, but are not limited to, current, voltage, inductance, and pulse commands.

The specific welding parameters controlled by the wireless remote control 50 are determined by the operator via the front panel control 42 on the power supply 12. The control panel 42 is of a design that is well known in the art and includes a plurality of actuators and selectors thereon. The precise mechanism built into the front panel control 42 can vary, but will allow the operator to select specific welding parameters controlled by the wireless remote control 50.

As noted above, not only may the welding-type system 10 be designed with a wireless remote control 50 and receiver 36, but it is also envisioned that existing welding-type systems may be modified with an assembly kit (assembly kit) to allow wireless remote control of the system. A wireless remote assembly kit (not shown) may be integrated with an existing welding-type system by operatively connecting receiver 36 with controller 13 of the welding-type power supply 12 via an existing connection port 37. The wireless remote control 50 is then configured to communicate with the receiver 36. The receiver 36 is configured to receive and transmit wireless signals from the control device 50 to the controller 13 to process the received wireless data to control the operation of the welding-type system 10 and to set or adjust these various welding-type parameters.

Those skilled in the art will readily appreciate that the aforementioned welding-type systems include not only welding equipment, but also any system that requires such accessories and/or high power output, such as heating and cutting systems. Those skilled in the art are familiar with such welding-type devices, and as used herein, terms of ordinary meaning are given to those skilled in the art of welding and cutting devices.

Therefore, the present invention, including welding-type systems, is equally applicable to any device requiring a high power output, including welding equipment, plasma cutters, induction heaters, and the like. Reference to welding power, welding type power, or welding equipment generally includes welding, cutting, or heating power. The description of the welding apparatus illustrates only one specific embodiment in which the invention may be practiced. The present invention is equally applicable to many high power systems, such as cutting, or any similar system.

Therefore, in accordance with one embodiment of the present invention, a welding-type system is disclosed. The welding-type system includes a power source having a controller that regulates a welding operation and a welding torch actuated by a trigger and connected to the power source. The system also includes a wireless remote control configured to remotely transmit signals for controlling a plurality of welding parameters in the welding system, and a receiver remote from the wireless remote control and configured to receive the signals and allow the controller to adjust at least one of the plurality of welding parameters in response to the signals. The receiver is further configured to engage with an attachment port on the power source, the attachment port configured to engage with the receiver and the control cable.

In accordance with another embodiment of the present invention, a wireless remote control kit for retrofitting a welding-type device is provided. The wireless remote control kit includes a wireless control device configured to transmit signals to control a plurality of welding parameters in a welding-type apparatus adapted to generate a welding-type power. The wireless remote control kit further includes a receiver remote from the wireless control device and configured to receive and transmit the signal to the welding-type device. The receiver is operatively connected to a controller disposed in the power source of the welding-type device.

In accordance with a further embodiment of the present invention, a method for adapting an existing welding-type system for use with a wireless remote control is disclosed. The method comprises the following steps: the method includes connecting a receiver to a welding-type power source via an existing control cable connection port, wirelessly transmitting a signal from a wireless remote control indicative of desired operating parameters of the welding-type system, remotely receiving the signal via the receiver, and controlling the welding-type system in accordance with data contained in the received wirelessly transmitted signal.

While the invention has been described in terms of the preferred embodiments, it is to be understood that the same, alternatives, and modifications, aside from those expressly stated, are possible within the scope of the appending claims.