Apparatus and method for brazing

Abstract

To provide brazing device and method.SOLUTION: A brazing system includes a controller circuit board (controller) having a processor and a memory. This system further includes fuel gas output, oxygen / air gas input, and oxygen / air gas output. This system further includes a touch screen display and a foot pedal which are respectively operatively connected to the controller. The controller is so configured as to story plural jobs of flame initial setting in a memory. An optional job of flame initial setting can be called from the controller circuit board, and can be periodically repeated according to stepping on the foot pedal. Each job corresponds to a series of joint brazing performed for a brazing assembly, and includes plural selectable flame initial settings. Each flame initial setting regulates flame setting based on a fuel gas flow rate and an oxygen / air gas flow rate.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This U.S. patent application claims priority and benefit from U.S. patent application Ser. No. 62 / 592,016, filed Nov. 29, 2017, the disclosure of which is incorporated herein by reference. U.S. Patent No. 8,444,041, filed Apr. 8, 2011, issued May 21, 2013, is incorporated herein by reference in its entirety.

[0002] SUMMARY OF THE DISCLOSURE The embodiments of the invention described herein generally relate to a brazing system with reproducible gas flow rate control using multiple gases and methods for achieving the same. [Background technology]

[0003] Brazing is one of the known methods of joining metal members together with a braze filler (i.e., a metal or alloy having a lower melting point than the metals being joined). Brazing typically involves the use of a torch with at least two needle restrictors that control the flow and ratio of at least two welding gases. One of the gases will include a combustible fuel gas, such as LP gas, natural gas, acetylene gas, methane, propane, butane, hydrogen, or a mixture or combination thereof, and the other gas will include a combustion support gas, such as oxygen or air. The needle restrictors are used to manually adjust the gas flow before and during brazing, as the pressure, flow rate, and / or quality of the gas may vary, leading in some cases to quality issues. Adjustments are required for a variety of reasons, including changes in external temperature, the total amount of gas used, or the amount of residual gas in the cylinder, and all variables that affect the gas flow rate. In addition, torch operators, even those with many years of experience, may have great difficulty in setting the needle valves and determining whether the gas mixture will produce a flame with an acceptable oxygen-to-fuel ratio.

[0004] In view of the above-mentioned problems and shortcomings of existing brazing systems with torches having multiple adjustable valves, the present application describes a brazing system and method that overcomes these shortcomings. Summary of the Invention [Means for solving the problem]

[0005] SUMMARY OF THE DISCLOSURE Embodiments of a brazing system and method are disclosed.

[0006] According to one embodiment, a single torch brazing system is provided. The single torch brazing system regulates brazing with a single brazing torch. The system includes a controller circuit board (controller) having a processor and a memory. The system also includes a fuel gas input, a fuel gas output, an oxygen / air gas input, and an oxygen / air gas output. As used herein, the term "oxygen / air gas" refers to either oxygen or air, which are non-fuel gases used by the system. The system further includes a touch screen display operably connected to the controller circuit board and a foot pedal operably connected to the controller circuit board. The controller circuit board is configured to store a plurality of flame initialization jobs in memory. Any job of the plurality of flame initialization jobs can be recalled from the controller circuit board (e.g., via the touch screen display) and repeated periodically in response to depressing the foot pedal. Each job of the plurality of flame initialization jobs corresponds to a series of joint brazes to be performed on the brazing assembly and includes a plurality of selectable flame initializations. Each flame initialization of the plurality of selectable flame initializations defines a flame setting based at least on a fuel gas flow rate and an oxygen / air gas flow rate. In one embodiment, the system includes a fuel encoder knob and an oxygen / air encoder knob. A flame default of a plurality of selectable flame defaults may be established in the memory of the controller circuit board by entering a setup mode of the controller circuit board via a touch screen display and using the fuel encoder knob and the oxygen / air encoder knob to independently adjust the flow rates of the fuel gas and the oxygen / air gas, respectively. In one embodiment, the system includes a robot operably connected to the controller circuit board via an automation interface. The controller circuit board is configured to communicate with a programmable logic controller of the robot holding the brazing torch via the automation interface to control the motion of the robot and synchronize the selected flame type with the brazing position of the robot during the brazing operation.In one embodiment, the system includes a controller circuit board and a mass flow controller operably connected between a fuel gas input and a fuel gas output. The mass flow controller is configured to monitor and adjust the flow rate of at least the fuel gas under the control of the controller circuit board. In one embodiment, the system includes a controller circuit board and a mass flow controller operably connected between an oxygen / air gas input and an oxygen / air gas output. The mass flow controller is configured to monitor and adjust the flow rate of at least the oxygen / air gas under the control of the controller circuit board. In one embodiment, the system includes a fuel gas mass flow controller and an oxygen / air gas mass flow controller configured to monitor and adjust the flow rate of at least the fuel gas and the oxygen / air gas to maintain a desired flame at a selected flame setting. The system includes a power supply board configured to provide power to at least the controller circuit board. In one embodiment, the system includes a wireless router. The wireless router is operably connected to an external computer, and the controller circuit board is configured to wirelessly communicate with the external computer via the wireless router for at least one of data collection by the external computer and software license management. In one embodiment, the wireless router is a Wi-Fi router and the controller circuit board is configured to wirelessly communicate with the external computer via the Wi-Fi router. In one embodiment, the external computer includes a dashboard user interface implemented as a software application running on the external computer as computer executable instructions. The dashboard user interface is configured to process collected data collected by the external computer from the controller circuit board for viewing and analysis by a user. The collected data may relate to at least one of the time the brazing system was on during the brazing process, the time gas was flowing during the brazing process, settings associated with what the brazing system was doing during the brazing process, and diagnostic information.

[0007] According to one embodiment, a multi-torch brazing system is provided. The multi-torch brazing system simultaneously regulates brazing by multiple brazing torches. The system includes a controller circuit board having a processor and a memory. The system also includes a touch screen display operably connected to the controller circuit board. The system further includes a single fuel gas input and multiple fuel gas outputs. The system also includes a fuel gas mass flow controller operably connected between the controller circuit board and the single fuel gas input and the multiple fuel gas outputs. The fuel gas mass flow controller is configured to independently monitor and adjust the flow rate of at least the fuel gas under the control of the controller circuit board. The system further includes a single oxygen / air gas input and multiple oxygen / air gas outputs. The system also includes an oxygen / air gas mass flow controller operably connected between the controller circuit board and the single oxygen / air gas input and the multiple oxygen / air gas outputs. The oxygen / air gas mass flow controller is configured to independently monitor and adjust the flow rate of at least the oxygen / air gas under the control of the controller circuit board. In one embodiment, the system further includes a fuel encoder knob and an oxygen / air encoder knob. Flame settings may be established in the memory of the controller circuit board of the multiple brazing torches by entering a setup mode of the controller circuit board via the touch screen display and using the fuel encoder knob and the oxygen / air encoder knob to independently adjust the fuel gas flow rate of each of the multiple fuel gas outputs and the oxygen / air gas flow rate of each of the multiple oxygen / air gas outputs. The fuel gas mass flow controller and the oxygen / air gas mass flow controller are configured to independently monitor and adjust under control of the control circuit board at least the fuel gas flow rate of each of the multiple fuel gas outputs and the oxygen / air gas flow rate of each of the multiple oxygen / air gas outputs to simultaneously maintain various desired flames corresponding to various selected flame settings of each of the multiple brazing torches.In one embodiment, the system also includes a first RS232 interface configured to operably connect the controller circuit board to the fuel gas mass flow controller and a second RS232 interface configured to operably connect the controller circuit board to the oxygen / air gas mass flow controller. In one embodiment, the plurality of fuel gas outputs are limited to three fuel gas outputs and the plurality of oxygen / air gas outputs are limited to three oxygen / air gas outputs. In one embodiment, the system further includes a wireless router. The wireless router is operably connected to an external computer. The controller circuit board is configured to wirelessly communicate with the external computer via the wireless router for at least one of data collection by the external computer and management of software licenses. In one embodiment, the wireless router is a Wi-Fi router and the controller circuit board is configured to wirelessly communicate with the external computer via the Wi-Fi router. The external computer includes a dashboard user interface implemented as a software application running on the external computer as computer executable instructions. The dashboard user interface is configured to process collected data collected by the external computer from the controller circuit board to be viewed and analyzed by a user. In one embodiment, the collected data is related to at least one of the time the brazing system was on during the brazing process, the time gas was flowing during the brazing process, settings associated with what the brazing system was doing during the brazing process, and diagnostic information.

[0008] These and other aspects will become evident in light of the accompanying drawings, detailed description, and appended claims.

[0009] At least one embodiment of the invention may take the physical form of the several parts and arrangement of parts that are described in detail herein and illustrated in the accompanying drawings that form a part hereof. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a side elevational view of a prior art brazing system in which flow control is achieved using a throttle valve located on the torch. [Diagram 2] 1 illustrates a single torch brazing system configuration mounted on a stand according to one embodiment of the present invention. [Diagram 3] 3 shows various elements of the single torch brazing system configuration of FIG. 2 that can be seen and accessed from a front view, an inlet side view, and an outlet side view of a brazing system according to one embodiment of the present invention. [Figure 4] 1 illustrates a multi-torch brazing system configuration mounted on a stand according to one embodiment of the present invention. [Diagram 5] 5 illustrates various elements of the multi-torch brazing system configuration of FIG. 4 that can be seen and accessed from the front, inlet side, and outlet side views of the brazing system according to one embodiment of the present invention. [Figure 6] 3 illustrates a single torch system showing various components and interfaces internal and external to the single torch configuration of FIG. 2 in accordance with one embodiment of the present invention. [Figure 7] 3 illustrates a single torch system showing various components and interfaces internal and external to the single torch configuration of FIG. 2 in accordance with one embodiment of the present invention. [Figure 8] 5 illustrates a multi-torch system showing various components and interfaces internal and external to the multi-torch configuration of FIG. 4 in accordance with one embodiment of the present invention. [Figure 9] 5 illustrates a multi-torch system showing various components and interfaces internal and external to the multi-torch configuration of FIG. 4 in accordance with one embodiment of the present invention. [Figure 10] 1 illustrates an embodiment of a brazing arrangement that wirelessly communicates with a server computer. [Figure 11] 1 illustrates one embodiment of a brazing arrangement that communicates with a server computer through an intermediate computer. [Figure 12] 1 illustrates one embodiment of a user computer in communication with a server computer over a computer network. [Figure 13]1 illustrates an embodiment of example screenshots provided by a dashboard user interface. [Figure 14] 1 illustrates an embodiment of example screenshots provided by a dashboard user interface. [Figure 15] 1 illustrates an embodiment of example screenshots provided by a dashboard user interface. [Figure 16] 1 illustrates an embodiment of example screenshots provided by a dashboard user interface. [Figure 17] 1 illustrates an embodiment of example screenshots provided by a dashboard user interface. [Figure 18A] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 18B] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 19A] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 19B] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 20] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 21] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 22] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 23] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 24] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Diagram 25] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 26A] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 26B] 5 illustrates an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4 showing process flow control. [Figure 27A] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Figure 27B] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Figure 28A] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Figure 28B] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Figure 29] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Figure 30A] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Figure 30B] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Diagram 31] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Diagram 32] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Diagram 33] 3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. [Diagram 34]3 illustrates an embodiment of a screenshot provided by the single torch configuration of FIG. 2 showing process flow control. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Exemplary embodiments of the present invention will now be described below by referring to the accompanying drawings. The exemplary embodiments described are intended to aid in understanding, and are not intended to limit the scope of the present invention in any manner. The same reference numerals refer to the same elements throughout the specification.

[0012] 1 shows a prior art brazing system 100 in which a throttle valve is located on the torch and includes a first gas source 105 and a second gas source 110, where the first gas source 105 provides oxygen or air and the second gas source 110 provides a fuel including at least one of acetylene, propane, natural gas or methane, propylene, hydrogen, butane, and mixtures thereof. A first gas hose 115 connects to the first gas source 105 and the brazing torch 120, and a second gas hose 125 connects to the second gas source 110 and the brazing torch 120.

[0013] In the embodiment shown, the brazing torch 120 includes a handle or torch body 130, an on / off switch 135, a first needle valve 140, a second needle valve 145, a brazing torch neck 150, and a brazing tip 155. To use the conventional brazing system 100, an operator opens valves on the first gas source 105 and the second gas source 110, opens the first needle valve 140 and the second needle valve 145 to form a combustible gas mixture, and ignites the mixed gas exiting the brazing tip 155. It is understood that the gas source may be from a gas tank with a pressure regulator or from a main supply line with a pressure regulator. After ignition, the brazing torch operator will make adjustments to the first needle valve 140 and the second needle valve 145 to address real or perceived inconsistencies in the brazing flame. Additionally, the needle valve setting can be altered due to fluctuations in gas pressure and flow rates and inconsistencies in the braze joint caused by imprecise gas mixtures. As discussed above, even the most experienced torch operators have difficulty setting a flame with a consistent oxygen to fuel ratio.

[0014] For example, an operator may have difficulty determining precisely whether the brazing flame from a torch is neutral or has the desired flame temperature or BTU output. Additionally, an operator may have great difficulty producing a consistent and repeatable flame with the same flame characteristics.

[0015] Again, the brazing system may include a first gas source and a second gas source, the first gas source being oxygen or air, and the second gas source being a fuel including at least one of acetylene, propane, natural gas, or methane, propylene, hydrogen, butane, or mixtures thereof. The gas source may be, for example, from a gas tank having a pressure regulator or from a main supply line having a pressure regulator. A first gas hose may connect to the first gas source and to the housing of the brazing system. A second gas hose may connect to the second gas source and to the housing. In some exemplary embodiments, the housing is constructed from and constructed of materials to meet NEMA 4X specifications.

[0016] In one embodiment, gas from a first gas source flows from the housing into a first brazing torch gas hose and gas from a second gas source flows from the housing into a second brazing torch gas hose. The first brazing torch gas hose and the second brazing torch gas hose connect to a brazing torch. Again, the brazing torch may include a handle, an operating trigger or on / off switch, a neck, and a brazing tip. The brazing torch also includes an internal portion where the gases mix before exiting the brazing torch at the brazing tip. An operator activates an operating trigger on the brazing torch to ignite the torch.

[0017] The ratio of the flow rate of at least the first gas to the flow rate of the second gas (also known as the oxygen-to-fuel ratio) may be determined and / or controlled according to an embodiment. Each of the fuel gases, including acetylene, propane, natural gas or methane, propylene, hydrogen, and butane, has a range of oxygen-to-fuel ratios that will generate a consistent brazing flame every time an operator lights the brazing torch. For example, the oxygen-to-fuel ratio may be set to reproduce a target and maximum oxidizing flame, a neutral flame, a charring flame, or any flame having characteristics between the above identified flames as known by those skilled in the art.

[0018] To provide additional context for various aspects of some embodiments of the present invention, the following discussion is intended to provide a brief, general description of a suitable computing environment in which various aspects of some embodiments of the present invention may be implemented. Those skilled in the art will recognize that various aspects of some embodiments of the present invention may also be implemented in combination with other program modules and / or as a combination of hardware and software. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks or implement particular data types.

[0019] Moreover, those skilled in the art will appreciate that the inventive methods may be performed by other computer system configurations including single-processor or multi-processor computer systems, minicomputers, mainframe computers, each of which may be operatively coupled to one or more associated devices, as well as personal computers, handheld computing devices, microprocessor-based or programmable consumer electronics devices, and the like. The illustrated aspects of some embodiments of the invention may also be practiced in distributed computing environments where some tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.

[0020] A computing device (e.g., a computer controller) or user interface may utilize an exemplary environment for implementing various aspects of some embodiments of the present invention, including a computer including a processing unit, a system memory, and a system bus. The system bus couples system components including, but not limited to, the system memory to the processing unit. The processing unit may be any of a variety of commercially available processors. Dual microprocessors and other multi-processor architectures may also be employed as the processing unit.

[0021] The system bus may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The system memory may include read only memory (ROM) and random access memory (RAM). For example, the basic input / output system (BIOS), containing the basic routines that help to transfer information between elements within the computer during start-up, is stored in ROM.

[0022] The computing device or user interface may further include hard disk drives, magnetic disk drives, for example for reading from and writing to removable disks, and optical disk drives, for example for reading CD-ROM disks or other optical media. The computing device or user interface may include at least some form of computer readable medium. The computer readable medium may be any available medium that can be accessed by a computer. By way of example, and not limitation, the computer readable medium may include computer storage media and communication media. Computer storage media includes volatile, non-volatile, removable, and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other magnetic storage devices, or any other medium that can be used to store desired information and that can be accessed by a user interface.

[0023] Communication media typically embodies computer-readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term "modulated data signal" means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer-readable media.

[0024] A number of program modules may be stored in the drive and RAM, including an operating system, one or more application programs, other program modules, and program data. The operating system in a computing device or user interface may be any of a number of commercially available operating systems.

[0025] In addition, a user may input commands and information into the computing device through a keyboard and a pointing device such as a mouse. Other input devices may include a microphone, an IR remote control, a trackball, a pen input device, a joystick, a game pad, a digitizing tablet, a satellite dish, a scanner, and the like. These and other input devices are often connected to the processing unit through a serial port interface coupled to the system bus, but may be connected by other interfaces such as a parallel port, a game port, a universal serial bus (USB), an IR interface, and / or various wireless technologies. A monitor or other type of display device may also be connected to the system bus through an interface such as a video adapter. A visual output may also be achieved through a remote display network protocol such as a remote desktop protocol, VNC, the X-Window System, and the like. In addition to a visual output, the computer or computing device may include other peripheral output devices such as speakers, printers, and the like.

[0026] A display may be employed in conjunction with the user interface to present data received electronically from the processing unit. For example, the display may be an LCD, plasma, CRT monitor, etc. that presents data electronically. Alternatively or in addition, the display may present the received data in hardcopy format, such as on a printer, facsimile, plotter, etc. The display may present data in any color and may receive data from the user interface via any wireless or hardwire protocol and / or standard.

[0027] A computing device may operate in a networked environment by using logical and / or physical connections to one or more remote computers. The remote computer may be a workstation, a server computer, a router, a personal computer, a microprocessor-based entertainment device, a peer device or other common network node and typically includes many or all of the elements described above in connection with a computer. The logical connections depicted include local area networks (LAN) and wide area networks (WAN). Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.

[0028] When used in a LAN networking environment, the computing device is connected to the local network through a network interface or adapter. When used in a WAN networking environment, the computing device typically includes a modem or is connected to a communication server on the LAN or has other means of establishing communications over the WAN, such as the Internet. In a network environment, program modules depicted relative to the computing device, or portions thereof, may be stored in the remote memory storage device. It will be appreciated that the network connections described herein are exemplary and other means of establishing a communications link between the computers may be used.

[0029] Several substantially automated brazing system embodiments are now described herein. According to one embodiment of the present invention, the indication of the flame type (neutral, oxidizing, or charring) is a function of the oxygen to fuel gas ratio, for example, as determined by the controller of the brazing system. However, the controller may also take into account the type of fuel utilized. That is, the ratio that produces some flame types for a first type of fuel will not be the same for a different type of fuel. In other words, a first gas ratio produces a neutral flame when using acetylene, but the same ratio may not produce a neutral flame when using another type of fuel gas, such as propane. Thus, the controller takes into account the type of fuel and the gas ratio when determining the flame type. Similarly, the range of gas ratios that produce neutral, oxidizing, or charring flame types will vary for each type of fuel gas used, and thus the controller takes these factors into account when determining the appropriate flame type (e.g., displaying the flame type).

[0030] A first embodiment of the substantially automated brazing system is a single torch brazing system configuration that includes units that support the operation of a single torch. The single torch configuration has a single oxygen / air gas input, a single oxygen / air gas output, a single fuel gas input, and a single fuel gas output. The fuel gas can be, for example, propane, natural gas, or hydrogen. Figure 2 shows a single torch unit configuration 200 mounted on a stand 210. Various views of the single torch configuration 200 are shown in Figure 2, including a front view 220, an inlet side view 230, an outlet side view 240, and a back view 250.

[0031] 3 shows various elements of the single torch configuration 200 that can be viewed and accessed from a front view 220, an inlet side view 230, and an outlet side view 240. The elements include a display touch screen 202, an oxygen / air encoder knob 204, a fuel encoder knob 206, an antenna 208 (e.g., a Wi-Fi antenna), a power switch 212, and a power indicator LED 214. The elements also include an inlet oxygen / air line (oxygen / air gas input) 216, an outlet oxygen / air line (oxygen / air gas output) 218, an inlet fuel line (fuel gas input) 222, and an outlet fuel line (fuel gas output) 224. The elements further include a handle 226, side louvers 228, and a wall mounting bracket 232. The elements also include a foot pedal connector 234, an AC supply input 236, and an automation interface 238.

[0032] A second embodiment of a substantially automated brazing system is a multi-torch brazing system configuration that includes a unit that supports the operation of multiple torches (e.g., three torches) and provides various tips and various settable flow rates for each torch. The multi-torch configuration has one oxygen / air gas input and one fuel gas input with multiple (e.g., three) controlled oxygen / air gas outputs and multiple (e.g., three) controlled fuel gas outputs to independently support each of the multiple (e.g., three) torches. The multi-torch configuration allows multiple brazing stations to be supported by a single unit, thus reducing the cost per station. FIG. 4 shows a multi-torch unit configuration 400 mounted on a stand 410. Various views of the multi-torch configuration 400 are shown in FIG. 4, including a front view 420, an inlet side view 430, an outlet side view 440, and a back view 450.

[0033] 5 shows various elements of the multi-torch configuration 400 that can be viewed and accessed from a front view 420, an inlet side view 430, and an outlet side view 440. The elements include a display touch screen 402, an oxygen / air encoder knob 404, a fuel encoder knob 406, an antenna (e.g., Wi-Fi antenna) 408, a power switch 412, and a power indicator LED 414. The elements also include an inlet oxygen / air line (oxygen / air gas input) 416, a plurality (e.g., three) of outlet oxygen / air lines (oxygen / air gas output) 418, an inlet fuel line (fuel gas input) 422, and a plurality (e.g., three) of outlet fuel lines (fuel gas output) 424. The elements further include a handle 426, side louvers 428, a wall mounting bracket 432, and an AC supply input 436.

[0034] 6 and 7 show an embodiment of a single torch system 600 illustrating various components and interfaces integrated internally or externally with the single torch unit configuration 200. Thus, terms such as "single torch configuration 200" and "single torch system 600" may be used later herein to refer to the integrated embodiment in some instances. The single torch system 600 includes a controller circuit board (aka control board or controller) 260 having memory 262 and processor 264, a power supply board 270, a touch screen display 202, a foot pedal 610, a wireless router (e.g., Wi-Fi router) 620, a robotic system 630 having a PLC 632, an automation (RS485) interface 238, an oxygen / air (oxygen or air) gas mass flow controller (MFC) 280 with a first RS232 interface 285, and a fuel gas MFC 290 with a second RS232 interface 295. The touch screen display 202 and the foot pedal 610 are operatively connected to the controller circuit board 260. The power supply board 270 also operably connects to at least the controller circuit board 260 for providing power to the controller circuit board 260. In one embodiment, the controller circuit board 260 distributes power to other components, such as, for example, the touchscreen display 202. In another embodiment, the power supply board 270 operably connects to the controller circuit board 260 as well as other components, such as, for example, the touchscreen display 202 for providing power to the controller circuit board 260.

[0035] The oxygen / air gas MFC 280 is operably connected to the controller circuit board 260 via an RS232 interface 285 and operably connected between the oxygen / air gas input 216 and the oxygen / air gas output 218. The oxygen / air gas MFC 280 is configured to monitor and regulate at least the flow rate of the oxygen / air gas under the control of the controller circuit board 260. Similarly, the fuel gas MFC 290 is operably connected to the controller circuit board 260 via an RS232 interface 295 and operably connected between the fuel gas input 222 and the fuel gas output 224. The fuel gas MFC 290 is configured to monitor and regulate at least the flow rate of the fuel gas under the control of the controller circuit board 260.

[0036] 8 and 9 show an embodiment of a multi-torch system 800 illustrating various components and interfaces that are internally or externally integrated with the multi-torch unit configuration 400. Thus, terms such as "multi-torch configuration 400" and "multi-torch system 800" may be used later herein to refer to the integrated embodiment in some instances. According to some embodiments, both the single torch configuration 200 and the multi-torch configuration 400 use a common controller circuit board 260 that may be configured to support either the single torch configuration 200 or the multi-torch configuration 400. In this manner, having a common controller circuit board between the two configurations may provide an economic advantage by allowing production volumes to be increased and costs associated with the components of the common controller circuit board to be reduced.

[0037] The multi-torch system 800 includes a controller circuit board (also known as a control board or controller) 260, a power supply board 470, a touchscreen display 402, a wireless router 820 (e.g., a Wi-Fi router), an oxygen / air (oxygen or air) gas mass flow controller (MFC) 480 with a first RS232 interface 485, and a fuel gas MFC 490 with a second RS232 interface 495. Each of the MFCs 480, 490 is configured to handle multiple (e.g., three) controlled output flows of gas. The touchscreen display 402 is operably connected to the controller circuit board 260. The power supply board 470 is also operably connected to at least the controller circuit board 260 to provide power. In one embodiment, the controller circuit board 260 distributes power to other components, such as, for example, the touchscreen display 402. In another embodiment, the power supply board 470 is operably connected to the controller circuit board 260 as well as other components, such as, for example, the touchscreen display 402 to provide power.

[0038] The oxygen / air gas MFC 480 is operably connected to the controller circuit board 260 via an RS232 interface 485 and operably connected between an oxygen / air gas input 416 and a plurality of oxygen / air gas outputs 418. The oxygen / air gas MFC 480 is configured to independently monitor and adjust the flow rate of at least the oxygen / air gas under the control of the controller circuit board 260 to independently support a plurality of brazing torches. Similarly, the fuel gas MFC 490 is operably connected to the controller circuit board 260 via an RS232 interface 495 and operably connected between a fuel gas input 422 and a plurality of fuel gas outputs 424. The fuel gas MFC 490 is configured to independently monitor and adjust the flow rate of at least the fuel gas under the control of the controller circuit board 260 to independently support a plurality of brazing torches.

[0039] The single torch configuration 200, according to one embodiment, provides multiple (e.g., five) flame initializations that can be changed and cycled through the foot pedal 610. In one embodiment, the controller circuit board 260 stores multiple flame initialization jobs in memory. Any of the flame initialization jobs can be invoked from the controller circuit board 260 (e.g., via the touch screen display 202) and cycled in response to depressing the foot pedal 610. Each job of the multiple jobs corresponds to a series of joint brazes to be performed on a brazing assembly and includes multiple selectable flame initializations. Each flame initialization defines a flame setting based on a fuel gas flow rate and an oxygen / air gas flow rate. A flame initialization can be established in the controller circuit board 260 memory for a job by entering a setup mode of the controller circuit board 260 via the touch screen display 202. The encoder knobs 204 / 206 on the front 220 of the unit 200 are used to independently adjust the flow rates of both oxygen / air gas and fuel gas for presets to establish a certain type of flame, such as a neutral flame, an oxidizing flame, or a carbonizing flame. The flame presets can be named and stored in the memory 262 (see FIG. 7 ) of the system 200. According to one embodiment, up to 100 flame presets can be established, and groups of five preset jobs can be formed from the 100 flame presets such that any job of presets can be recalled and repeated periodically by pressing the foot pedal 610. In this way, a series of joint brazings, each of which may require a different flame setting, performed on a brazing assembly can be quickly and easily accommodated.

[0040] According to another embodiment, the multi-torch configuration 400 provides similar initial settings and jobs that can be set up and used by each of the multiple torches. For example, flame settings can be established in the memory 262 of the controller circuit board 260 for multiple brazing torches by entering a setup mode of the controller circuit board 260 via the touch screen display 402. The fuel encoder knob 406 and the oxygen / air encoder knob 404 can then be used to independently adjust the fuel gas flow rate of each of the multiple fuel gas outputs 424 and the oxygen / air gas flow rate of each of the multiple oxygen / air gas outputs 418.

[0041] In one embodiment, the gas flows are controlled via mass flow controllers (e.g., 280, 290 in a single torch configuration; 480, 490 in a multi-torch configuration). The MFCs 480, 490 are each configured to control three gas output flows. The single torch configuration 200 and the multi-torch configuration 400 each include integrated software having computer executable instructions stored in memory 262 (see FIGS. 7 and 9) and configured to execute on the processor 264 (see FIGS. 7 and 9) of the common controller circuit board 260. The integrated software automatically monitors the sensed gas flows and makes adjustments to the mass flow controllers (e.g., 280, 290, or 480, 490) in order to generate and maintain a desired (selected) flame, according to one embodiment. The integrated software is configured to react in real time to changes in gas flows.

[0042] For example, the fuel gas MFC 290 and the oxygen / air MFC 280 are configured to monitor and adjust at least the flow rate of the fuel gas and the flow rate of the oxygen / air gas under the control of the controller circuit board 260 to maintain a desired flame corresponding to a selected flame setting. Similarly, the fuel gas MFC 490 and the oxygen / air gas MFC 480 are configured to independently monitor and adjust at least the flow rate of the fuel gas of each of the plurality of fuel gas outputs 424 and the flow rate of the oxygen / air gas of each of the plurality of oxygen / air gas outputs 418 under the control of the control circuit board 260 to simultaneously maintain various desired flames corresponding to various selected flame settings for each of the plurality of brazing torches.

[0043] In one embodiment, the oxygen / air gas mass flow controller is configured to provide controlled flow ranges of 2-100 standard cubic feet per hour (SCFH) of oxygen and 2-100 SCFH of air. In one embodiment, the fuel gas mass flow controller is configured to provide controlled flow ranges of 2-100 SCFH of methane, 1.2-60 SCFH of propane, 2-100 SCFH of acetylene, 2-100 SCFH of hydrogen, 1.4-70 SCFH of propylene, and 1-44 SCFH of butane.

[0044] In one embodiment (e.g., single torch configuration), the brazing system includes an RS485 communication port (automation interface) 238 for remote control of the brazing system by a programmable logic controller (PLC) (e.g., PLC 632 of robotic system 630). The automation interface 238 is operatively connected to the controller circuit board 260. In this manner, brazing can be performed automatically by the robotic system 630 with the PLC 632 (which controls the robotic motion of the robotic system 630, which holds the brazing torch) while also remotely controlling the brazing system (e.g., to invoke different pre-set flame types during the robotic brazing process performed by the robot on the brazing assembly). According to one embodiment, the PLC 632 effectively synchronizes the selected flame type with the robotic brazing position.

[0045] According to one embodiment, both the single torch configuration 200 and the multi-torch configuration 400 support wireless communication capabilities (e.g., via Wi-Fi router 620 or 820) and are configured to communicate with an external server computer 1000 for data collection (e.g., to obtain collected data from the controller circuit board 260) and software license management, as shown in FIG. 10. For example, in one embodiment of the single torch configuration 200, the wireless router 620 is operably connected to the external server computer 1000. The controller circuit board 260 operably connected to the antenna 208 is configured to wirelessly communicate with the external server computer 1000 via the wireless router 620. In one embodiment of the multi-torch configuration 400, the wireless router 820 is operably connected to the external server computer 1000. The controller circuit board 260 operably connected to the antenna 408 is configured to wirelessly communicate with the external server computer 1000 via the wireless router 820. According to one embodiment, an external server computer 1000 is present on-site and within wireless communication range of the brazing system 200 / 400. According to another embodiment, the brazing system 200 / 400 may wirelessly communicate with an intermediate computer system 1100 (see FIG. 11), which may then communicate with a server computer 1000 located off-site (e.g., in the "cloud" 1110).

[0046] During data collection, a data stream is wirelessly transmitted from the brazing system to the server computer 1000. According to one embodiment, the data stream may be transmitted at a specific configurable time (e.g., when the brazing process is completed or at the end of the work day). According to another embodiment, the data stream may be transmitted continuously during the brazing process. This data stream may include, for example, data related to the time the brazing system was on during the brazing process, the time gas was flowing during the brazing process, settings related to what the brazing system was doing during the brazing process as well as other monitoring or diagnostic information. According to various embodiments, the server computer 1000 may analyze the brazing process or the data may be extracted from the server computer 1000 by another system that may analyze the brazing process. According to one embodiment, the data on the server computer 1000 where the web page resides is presented to the user via a web interface.

[0047] According to one embodiment, the server computer 1000 is configured to be accessed by an external user and further configured to provide collected data (e.g., data collected from the controller circuit board 260) to a dashboard user interface that allows the user to view and analyze the collected data on, for example, their desktop computer 1200 (see FIG. 12). The user's computer 1200 may access the server computer 1000 through an intermediate computer network 1210 (e.g., a LAN, a WAN, the Internet, or some combination thereof). According to one embodiment, the dashboard user interface is provided by a software application running on the user's computer 1200. In another embodiment, the dashboard user interface is provided by the server computer 1000, and the user easily accesses the dashboard user interface, for example, through a web browser on the user's computer 1200. The dashboard user interface is configured to process the collected data collected from the controller circuit board 260 such that the collected data can be viewed and analyzed by the user.

[0048] 13-17 show embodiments of example screenshots provided by the dashboard user interface. As shown in FIG. 13, the screenshots of the dashboard user interface may be accessed based on date and time (see highlighted days within the date range). The highlighted day is 10-16-17, and the date range extends from 10-15-17 to 10-19-17. The screenshot of FIG. 13 shows the "operation factor" (the percentage of time the brazing system is on or active) of the brazing system. A starting operation factor (40%) for a start date of 10-15-17 and an ending operation factor (50%) for an end date of 10-19-17 are shown, along with a range of operation factors (40%-50%) across the date range. FIG. 13 also shows the composite operation factor by hour for each of the five days within the date range.

[0049] FIG. 14 shows the average operating factor over all five days in the date range from 8:00 AM to 3:00 PM along with the daily trend of the operating factor over all five days. FIG. 15 shows the operating factor by hour for the brazing system for the date 10-16-17. FIG. 16 shows the operating factor by hour for three different brazing systems for the date 10-19-17. FIG. 17 shows the projections of overhead (OH) costs, labor costs, and savings for the brazing system. According to other embodiments, other types of screenshots provided by the dashboard user interface are possible as well.

[0050] In one embodiment, a licensed brazing system cannot be operated by an operator in a licensed mode unless a wireless connection (e.g., a Wi-Fi connection) is established with the server computer to establish the validity of the license. A valid license effectively permits an operator to use the brazing system. The license may be valid for a fixed period of time or may need to be renewed to allow continued use. Otherwise, according to one embodiment, if the license becomes invalid, the brazing system will revert to a restricted mode of operation, preventing the operator from using some functions of the brazing system.

[0051] 18A-26B show an embodiment of a screenshot provided by the multi-torch configuration of FIG. 4, illustrating process flow control. FIGS. 18A and 18B show an embodiment of a process flow for initial input to the multi-torch configuration. The process flow of FIGS. 18A and 18B includes steps of setting a machine ID, configuring Wi-Fi, validating a license, and setting a server upload time. FIGS. 19A and 19B show an embodiment of a process flow for the absence of a valid license for the multi-torch configuration. The process flow of FIGS. 19A and 19B includes steps of updating a license and configuring Wi-Fi. FIGS. 20-26B show an embodiment of a process flow for the home screen, main menu, and active license of the multi-torch configuration, including production mode, setup mode, and demo mode. Various process flow functions include, for example, flame setup, torch selection, flame setting selection, Wi-Fi configuration, license settings, server upload time, and display options. According to other embodiments, other process flow functions are possible as well.

[0052] 27A-34 show an embodiment of screenshots provided by the single torch configuration of FIG. 2, illustrating process flow control. FIGS. 27A and 27B show an embodiment of a process flow for initial entry into the single torch configuration. The process flow of FIGS. 27A and 27B includes steps of setting machine ID, configuring Wi-Fi, validating license, and setting server upload time. FIGS. 28A and 28B show an embodiment of a process flow for the absence of a valid license for the single torch configuration. The process flow of FIGS. 28A and 28B includes steps of updating license and configuring Wi-Fi. FIGS. 29-34 show an embodiment of a process flow for the home screen, main menu, and active license for the single torch configuration, including production mode, setup mode, and demo mode. Various process flow functions include, for example, flame setup, job setup, torch selection, flame settings selection, Wi-Fi configuration, license settings, server upload time, and display options. According to other embodiments, other process flow functions are possible as well.

[0053] Although the disclosed embodiments have been shown and described in considerable detail, it is not intended to limit or in any manner restrict the scope of the appended claims to such details. It is, of course, impossible to describe every conceivable combination of parts or methodologies for the purpose of describing various aspects of the subject matter. Thus, the disclosure is not limited to the specific details or illustrative examples shown and described. The disclosure is therefore intended to embrace such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims that satisfy the subject matter requirements of the statute of the U.S. Code, Title 35, Section 101. The above description of specific embodiments has been given by way of example. Given the disclosure, those skilled in the art will not only understand the general inventive concept and its attendant advantages, but will also find apparent various changes and modifications to the disclosed structures and methods. It is, therefore, sought to cover all such changes and modifications, and equivalents thereof, that fall within the spirit and scope of the general inventive concept as defined by the appended claims. [Explanation of symbols]

[0054] 100 Brazing System 105 First Gas Source 110 Secondary Gas Source 115 First Gas Hose 120 Brazing Torch 125 Second Gas Hose 130 Torch body 135 On / Off Switch 140 First needle valve 145 Second needle valve 150 Brazing Torch Neck 155 Brazed tip 200 Single Torch Unit Configuration 200” Single Torch Configuration 202 Touch Screen Display 204 Oxygen / Air Encoder Knob 206 Fuel Encoder Knob 208 Antenna 210 Stand 212 Power Switch 214 Power indicator LED 216 Inlet oxygen / air line 218 Outlet Oxygen / Air Line 220 Front view 222 Inlet fuel line 224 Outlet fuel line 226 Handle 228 Side Louver 230 Entrance side view 232 Mounting bracket 234 Foot Pedal Connector 236 AC supply input 238 Automation Interface 240 Exit side view 250 Rear view 260 Controller Circuit Board 262 Memory 264 Processor 270 Power Board 280 Oxygen Gas MFC 285 1st RS232 interface 290 Fuel Gas MFC 295 Second RS232 Interface 400 Multi-torch unit configuration 400” Multi-Torch Configuration 402 Touch Screen Display 404 Oxygen / Air Encoder Knob 406 Fuel Encoder Knob 408 Antenna 410 Stand 412 Power Switch 414 Power indicator LED 416 Inlet Oxygen / Air Line 418 Outlet Oxygen / Air Line 420 Front view 422 inlet fuel line 424 Outlet Fuel Line 426 Handle 428 Side Louver 430 Entrance side view 432 Mounting Bracket 436 AC supply input 440 Exit side view 450 Rear view 470 Power Board 480 Oxygen Gas MFC 485 1st RS232 interface 490 Fuel Gas MFC 495 Second RS232 Interface 600 Single Torch System 600” Single Torch Configuration 610 Foot Pedal 620 Wi-Fi Router 630 Robot System 632 PLC 800 Multi-Torch System 800” Multi-Torch System 820 Wi-Fi Router 1000 external server computers 1100 Intermediate Computer System 1110 Cloud 1200 User Computers 1210 LAN / WAN / Internet MFC Mass Flow Controller PLC Programmable Logic Controller

Claims

1. 1. A torch brazing system, comprising: A touch screen display; a controller circuit board having a processor and a memory, the controller circuit board configured to support a single torch configuration or a multi-torch configuration, the single torch configuration including a first integrated software having first computer executable instructions stored in the memory and configured to run on the processor, and the multi-torch configuration including a second integrated software having second computer executable instructions stored in the memory and configured to run on the processor; Including, the controller circuit board is connected to the touch screen display and configured to enable user interaction with the controller circuit board via the touch screen display; A torch brazing system, wherein the multi-torch configuration supports independent setting of multiple brazing torches and simultaneous use of the multiple brazing torches by multiple users during multiple independent brazing processes.

2. 10. The torch brazing system of claim 1, wherein the torch brazing system is one of a single torch brazing system or a multi-torch brazing system, the single torch brazing system and the multi-torch brazing system having at least some controllable hardware elements that differ from one another.

3. 3. The torch brazing system of claim 2, wherein said controller circuit board is configured to control controllable hardware elements of said single torch brazing system when said controller circuit board is installed in said single torch brazing system and said controller circuit board is configured in said single torch configuration.

4. 3. The torch brazing system of claim 2, wherein said controller circuit board is configured to control controllable hardware elements of said multi-torch brazing system when said controller circuit board is installed in said multi-torch brazing system and said controller circuit board is configured in said multi-torch configuration.

5. 10. The torch brazing system of claim 1, wherein said controller circuit board is configured to provide a home screen and a main menu and to support user interaction in production mode, setup mode and demo mode via at least said touch screen display.

6. 2. The torch brazing system of claim 1, further comprising a robot connected to said controller circuit board via an automation interface, said controller circuit board configured to communicate with a programmable logic controller of said robot holding a brazing torch via said automation interface to control movement of said robot and synchronize a selected flame type to a brazing position of said robot during a brazing operation.

7. 10. The torch brazing system of claim 1, further comprising a fuel gas mass flow controller and an oxygen / air gas mass flow controller configured to monitor and adjust at least a fuel gas flow rate and an oxygen / air gas flow rate to maintain a desired flame corresponding to a selected flame setting.

8. 2. The torch brazing system of claim 1, further comprising a fuel gas mass flow controller and an oxygen / air gas mass flow controller configured to at least independently monitor and adjust a flow rate of fuel gas for each of a plurality of fuel gas outputs of the system and a flow rate of oxygen / air gas for each of a plurality of oxygen / air gas outputs of the system under the control of the controller circuit board in the multi-torch configuration to simultaneously maintain different desired flames corresponding to different selected flame settings for each of the plurality of brazing torches.

9. The torch brazing system of claim 1 , wherein the controller circuit board provides a first process flow for the single torch configuration and a second process flow for the multi-torch configuration.

10. 10. The torch brazing system of claim 9, wherein the first process flow includes at least one function of flame setting, job setting, torch selection, flame setting selection, WiFi setting, software license activation, setting a server upload time for uploading collected data, and selecting display options.

11. 10. The torch brazing system of claim 9, wherein the second process flow includes at least one function of flame setting, job setting, torch selection, flame setting selection, WiFi setting, software license activation, setting a server upload time for uploading collected data, and display option selection.

12. The torch brazing system of claim 1 , wherein the controller circuit board is configured to control a process flow, the process flow including initial inputs to the torch brazing system by a user.

13. 13. The torch brazing system of claim 12, wherein the initial inputs to the torch brazing system include at least one of a user setting of a machine ID, a user setting of a WiFi, a user verification of a software license, and a user setting of a server upload time for when to upload collected data collected by the controller circuit board.

14. the controller circuit board is configured to store a plurality of flame initialization jobs in the memory; Any one of the plurality of flame initial setting jobs can be called from the controller circuit board; each job of the plurality of flame initialization jobs corresponds to a sequence of joint brazing to be performed on a brazing assembly and includes a plurality of selectable flame initialization jobs; The torch brazing system of claim 1 , wherein each of the plurality of selectable flame initializations defines a flame setting based on at least a fuel gas flow rate and an oxygen / air gas flow rate.

15. 15. The torch brazing system of claim 14, further comprising a fuel encoder knob and an oxygen / air encoder knob, wherein flame defaults of the plurality of selectable flame defaults can be established in the memory of the controller circuit board by entering a setup mode of the controller circuit board via the touch screen display and using the fuel encoder knob and the oxygen / air encoder knob to independently adjust flow rates of each of the fuel gas and the oxygen / air gas.

16. 2. The torch brazing system of claim 1, further comprising a wireless router and an external computer, the wireless router connected to the external computer, and the controller circuit board configured to wirelessly communicate with the external computer via the wireless router for at least one of data collection and software license management by the external computer.

17. The torch brazing system of claim 16, wherein said wireless router is a Wi-Fi router, and said controller circuit board is configured to wirelessly communicate with said external computer via said Wi-Fi router.

18. the external computer includes a dashboard user interface implemented as a software application that executes on the external computer as third computer-executable instructions; 17. The torch brazing system of claim 16, wherein the dashboard user interface is configured to process collected data collected by the external computer from the controller circuit board for viewing and analysis by a user.

19. 20. The torch brazing system of claim 18, wherein the collected data relates to at least one of the time the brazing system was on during the brazing process, the time gas was flowing during the brazing process, settings and diagnostic information associated with what the brazing system was doing during the brazing process.

20. 20. The torch brazing system of claim 18, wherein the dashboard user interface is configured to be accessed based on a date indicative of an operational factor of the torch brazing system, the operational factor being a percentage of time the brazing system is on or operational.

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