Weld cable communications controller module

Patent metadata

Field	Value
Publication number	US-10758994-B2
Application number	US-201314089184-A
Country	US
Kind code	B2
Filing date	Nov 25, 2013
Priority date	Apr 16, 2004
Publication date	Sep 1, 2020
Grant date	Sep 1, 2020

Abstract

The present invention is directed to a system and method of remotely controlling a welding machine with command signals transmitted to the welding power source across a weld cable connecting the power source to a remote device, such a wire feeder. A transmitter transmits the control commands containing desired welding operational parameters to a receiver disposed in the power source across a weld cable also designed to carry welding power from the power source to the wire feeder.

First claim

What is claimed is:

1. A welding system comprising:
a power source comprising:
a primary power supply configured to deliver welding power for a welding process via a welding circuit at least partially established by a weld cable;
a primary contactor to control the welding power across the weld cable; and
a secondary power supply configured to provide power for communication of data signals via the weld cable;

a remote device including a wire feeder operably connected to receive the welding power from the primary power supply via the weld cable; and
a communications controller disposed in a housing external to and separate from both the power source and the remote device, wherein the communications controller is configured to couple to the weld cable between the power source and the remote device, and to communicate control commands to or from the power source and the remote device via the weld cable and the welding circuit that is at least partially established by the weld cable that delivers the welding power from the primary power supply to the remote device.

2. The welding system of claim 1 , wherein the wire feeder is a voltage-sensed wire feeder.

3. The welding system of claim 1 , wherein the housing is a retrofit kit configured to be secured to an external surface of the power source.

4. The welding system of claim 1 , wherein the housing is a retrofit kit configured to be secured to an external surface of the remote device.

5. The welding system of claim 1 , wherein the housing comprises a multi-pin connector configured to secure the housing to an external surface of the power source or the remote device and to facilitate communication of the control commands.

6. The welding system of claim 1 , wherein the communications controller is configured to only communicate control commands via the weld cable when the remote device is at idle.

7. The welding system of claim 1 , wherein the communications controller is configured to communicate control commands via the weld cable during an active welding process.

8. The welding system of claim 1 , wherein the control commands include desired operating parameters for the power source for the welding process.

9. The welding system of claim 8 , wherein the desired operation parameters include a desired arc voltage.

10. A welding system comprising:
a power source comprising:
a primary power supply configured to provide welding power for a welding operation via a weld cable and
a primary contactor to control the welding power across the weld cable;
a secondary power supply configured to provide power for communication of data signals via the weld cable; and

a communications controller configured to be coupled to a weld cable between and external to the power source and a remote device including a wire feeder when the power source and the remote device are operatively connected via the weld cable, wherein the weld cable is configured to provide welding power suitable for a welding operation from the power source to the remote device via a welding circuit at least partially established by the weld cable, and wherein the communications controller is configured to communicate encoded control commands between the power source and the remote device via the welding circuit that is at least partially established by the weld cable that provides the welding power from the power source to the remote device.

11. The welding system of claim 10 , wherein the wire feeder is a voltage-sensed wire feeder.

12. The welding system of claim 10 , wherein the communications controller is a retrofit kit configured to be secured to an external surface of the power source.

13. The welding system of claim 10 , wherein the communications controller is a retrofit kit configured to be secured to an external surface of the remote device.

14. The welding system of claim 10 , wherein the communications controller comprises a multi-pin connector configured to secure the communications controller to an external surface of the power source or the remote device and to facilitate communication of the control commands.

15. The welding system of claim 10 , wherein the communications controller is configured to only communicate control commands via the weld cable when the remote device is at idle.

16. A welding system comprising:
a power source comprising:
a primary power supply configured to provide welding power suitable for a welding operation via a weld cable;
a primary contactor to control the welding power across the weld cable; and
a secondary power supply configured to provide power for communication of data signals via the weld cable and a secondary contactor to control the data signals across the weld cable;

a voltage sensing wire feeder configured to receive the welding power from the power source via a welding circuit at least partially established by the weld cable and a secondary work weld cable to provide the welding power along with welding wire for the welding operation; and
a controller configured to receive the welding power and data signals from the power source, and to transmit the welding power and the data signals to the voltage sensing wire feeder via the welding circuit that is at least partially established by the weld cable and the secondary work weld cable that provides the welding power from the power source to the voltage sensing wire feeder.

17. The welding system of claim 16 , wherein the communications controller is further configured to:
receive a command signal from the voltage sensing wire feeder over the weld cable or the secondary work weld cable to provide the welding power; and
provide welding power through the weld cable or the secondary work weld cable in response to the command signal.

18. The welding system of claim 17 , wherein the controller is further configured to regulate the power source such that the welding power is not provided until the command signal is triggered by a welding torch thereby initiating a welding process.

Assignees

• Illinois Tool Works

Inventors

• Ott Brian Lee

Classifications

• B23K9/124

  Circuits or methods for feeding welding wire · CPC title

• B23K9/1087 Primary

  Arc welding using remote control · CPC title

• B23K9/125

  Feeding of electrodes (for stabilising arc B23K9/073) · CPC title