Welding electrical control systems, devices, and methods

Abstract

An apparatus is disclosed. The apparatus has a power source, a control device connected to the power source, a welding device selectively connected to the power source via the control device, and a switch connected between the control device and the welding device. The control device includes a time delay relay that measures a predetermined time period. The switch remains in a closed position when the predetermined time period expires and the welding device is producing a welding arc. The switch switches from the closed position to an open position when the predetermined time period expires and the welding device stops producing the welding arc. The control device delivers current from the power source to the welding device when the switch is in the closed position and blocks current from the power source to the welding device when the switch is in the open position.

Description

TECHNICAL FIELD

[0001] Various embodiments relate generally to control systems, devices, and methods, and more particularly, to a welding electrical control system, device, and method. BACKGROUND

[0002] Welding joins materials based on a welding process that uses high temperatures to melt or join materials. Electric welding devices used in industries and activities such as construction, manufacturing, and repair can use various energy sources to produce high temperatures, and electric welding devices consume relatively large amounts of electrical energy.

[0003] Operators of welding devices can be skilled artisans known as welders. Welders can weld materials using various techniques that employ a welding torch or gun powered by a welding device to heat materials to be joined.

[0004] As welders work, welders can move welding torches or guns between work locations, or reposition welding torches or guns to access various items to be welded. In some cases (e.g., manufacturing), welding devices can be continuously powered for extended periods of time even when welders are not welding. Welding devices can remain powered when welders are not welding, whether welders are moving between work projects or between shifts. In extended use scenarios, welding devices can remain powered intermittently as different welders work around the clock during scheduled shifts. Businesses that operate welding devices can incur substantial excess costs for electrical power consumed by welding devices when welders are not actively welding, or between scheduled shifts.

[0005] Conventional welding power control devices that control welding power supplies based on operating states of welding guns have limitations. For example, some welding power control devices can reduce power when welding devices are idle, but can not disconnect or not fully disconnect power supplies. For example, such welding power control implementations can result in increased safety risks for device operators due to reduced but not disconnected or not fully disconnected power to welding devices when welding devices are not welding. In an illustrative example, control designs that reduce but do not disconnect or not fully disconnect welding power to welding devices when welding devices are idle can result in wasted energy by welding devices that continue to be powered at reduced levels (e.g., when welding devices are idle).

[0006] For example, U.S. Patent No. 2,170,861 entitled "Electric Apparatus Power Saver" describes a welding power control that automatically starts and stops the welding power to a welding apparatus when welding activity is suspended or resumed based on reducing the power to the welding apparatus when the welding apparatus is idle. However, for example, U.S. Patent No. 2,170,861 does not appear to disclose, for example, completely disconnecting the welding power when the welding apparatus is not welding; reconnecting the welding power to the welding apparatus when the welding apparatus contacts a workpiece to be welded; and maintaining the welding power to the welding apparatus based on the current flowing through the workpiece from the welding apparatus when the welder is welding.

[0007] For another example, U.S. Patent No. 2,499,635 entitled "Automatic self-starting and stopping system for arc welding installations" describes a welding power control that automatically starts and stops a system for a welding installation to reduce the power to the welding apparatus when the welding apparatus is idle and allows the welder to resume operation by contacting the welding apparatus to a workpiece. However, U.S. Patent No. 2,499,635 does not appear to disclose, for example, completely disconnecting the welding power when the welding apparatus is not welding; reconnecting the welding power to the welding apparatus when the welding apparatus contacts a workpiece to be welded; and maintaining the welding power to the welding apparatus based on the current flowing through the workpiece from the welding apparatus when the welder is welding.

[0008] For yet another example, U.S. Patent No. 3,748,561 entitled "Remote starting control circuit for welder power supply" describes a welding power control that reduces the power to a welding apparatus when the welding apparatus is idle, allows the welding apparatus to be started remotely to resume power for a predetermined time, and restarts the apparatus in response to contact between the welding apparatus and a workpiece. However, U.S. Patent No. 3,748,561 does not appear to disclose, for example, completely disconnecting the welding power when the welding apparatus is not welding; reconnecting the welding power to the welding apparatus when the welding apparatus contacts a workpiece to be welded; and maintaining the welding power to the welding apparatus based on the current flowing through the workpiece from the welding apparatus when the welder is welding.

[0009] The exemplary disclosed systems, apparatuses, and methods are directed to overcoming one or more of the disadvantages of the prior art and / or other deficiencies. SUMMARY

[0010] In one example aspect, the present disclosure relates to an apparatus. The apparatus includes a power source, a control device connected to the power source, a welding device selectively connected to the power source via the control device, and a switch connected between the control device and the welding device. The control device includes a time delay relay that measures a predetermined time period. The switch remains in a closed position when the predetermined time period expires and the welding device is producing a welding arc. The switch switches from the closed position to an open position when the predetermined time period expires and the welding device stops producing the welding arc. The control device transmits current from the power source to the welding device when the switch is in the closed position and blocks current from the power source to the welding device when the switch is in the open position.

[0011] In another example aspect, the present disclosure relates to a method. The method includes providing a power source and a welding device, electrically setting a control device between the power source and the welding device, setting a switch between the control device and the welding device, and measuring a predetermined time period with the control device. The method also includes maintaining the switch in a closed position when the predetermined time period expires and the welding device is producing a welding arc, switching the switch from the closed position to an open position when the predetermined time period expires and the welding device stops producing the welding arc, transmitting current from the power source to the welding device via the control device when the switch is closed, and blocking current from the power source to the welding device via the control device when the switch is open. BRIEF DESCRIPTION OF DRAWINGS

[0012] Figure 1 A schematic diagram of an example disclosed system illustrating at least some example embodiments of the present disclosure;

[0013] Figure 2 A schematic diagram of an example disclosed system illustrating at least some example embodiments of the present disclosure;

[0014] Figure 3 A perspective view of an example disclosed system illustrating at least some example embodiments of the present disclosure; and

[0015] Figure 4 An example process illustrating at least some example embodiments of the present disclosure.

[0016] Like reference numbers in different drawings represent the same or similar elements. DETAILED DESCRIPTION

[0017] The example disclosed systems, apparatuses, and methods can be an operable welding electrical control system configured to save welding electrical power, reduce welding costs, and improve welding safety by disconnecting a welding gun's welding device power source when the welding gun is idle and automatically reconnecting the welding gun power source, for example, when an unenergized welding gun contacts a workpiece to be welded (e.g., in response to a sensed current in a magnetic switch magnetically engaged with the workpiece).Figure 1 An exemplary system 100 is illustrated. System 100 may include control devices such as welding electrical control devices (e.g., welding electrical control 110), power supplies such as welding power source 115, and welding apparatus such as welding torch 120. Welding electrical control 110 can control the operation of welding torch 120, and welding power source 115 can supply power to system 100.

[0018] The welding power source 115 can be any suitable power source for powering system 100. For example, the welding power source 115 can be any suitable AC or DC power source for powering system 100. In at least some exemplary embodiments, the welding power source 115 may include a DC generator, a DC inverter, an AC transformer, an AC / DC transformer rectifier, and / or a DC rectifier. For example, the welding power source 115 may include a power supply, an engine, a motor, a battery, and / or any other desired power component or power source.

[0019] The welding torch 120 can be any suitable component for welding materials (e.g., a welding gun or welding torch). Figure 1 As shown, welding torch 120 can weld workpiece 125 via electric arc 130. For example, welding torch 120 can be a welding torch or torch used for plasma arc welding, gas shielded metal arc welding, tungsten inert gas welding, metal shielded arc welding, atomic hydrogen welding, flux-cored arc welding, and / or energy beam welding. Welding torch 120 can include any suitable type of welding torch or torch, such as a jet torch or a pressurized torch. Welding torch 120 can include any suitable low-pressure or medium-pressure torch or torch. In at least some exemplary embodiments, welding torch 120 can be an oxy-acetylene torch, a brazing torch, a propane torch, or a Mapp torch.

[0020] Figure 2 A schematic diagram of an exemplary disclosed welding electrical control 110 is shown. The welding electrical control 110 can be configured, for example, to save welding power, reduce welding costs, and improve welding safety by disconnecting the welding equipment power supply to the welding torch 120 when the torch 120 is idle and automatically reconnecting the power supply to the torch 120 when the unpowered torch 120 (e.g., by a user) presses against the workpiece 125 to be welded via the arc 130. The power supply can be connected and disconnected based on (e.g., in response to) current sensed in an exemplary disclosed magnetic switch that is magnetically engaged with the workpiece 125.

[0021] like Figure 2As shown, the example disclosed welding electrical control 110 can include a power input 205 connected to a transformer 210. In at least some example embodiments, the transformer 210 can be a three-phase step-down transformer configured to transform 480 VAC to a 120 VAC power source (e.g., or any other suitable level of VAC) connected to a time delay relay 215, a contactor 220, a current sensor input 225, and a power output 230. Also in at least some example embodiments, the transformer 210 can be a single-phase transformer. Figure 2 The tap voltages shown in connection with the transformer 210 are exemplary. Any other suitable voltages can also be used with the transformer 210 and / or other components of the system 100. The time delay relay 215 can be any suitable switch or relay (e.g., an electrical switch or relay) for operating with components of the welding electrical control 110. For example, the time delay relay 215 can be a digital solid state relay, a motor drive relay, an analog solid state relay, or a thermostat relay. The contactor 220 can be any suitable electrical component for controlling (e.g., turning on and off) the example disclosed circuit. For example, the contactor 220 can include a coil or electromagnet. The contactor 220 may, for example, be a hand controller, a magnetic contactor, or a knife switch. The current sensor input 225 can be any suitable component for electrically connecting to and / or receiving input from the example disclosed magnetic switch. The power output 230 can be any suitable electrical component for electrically connecting to the welding gun 120 and selectively providing or connecting power or current from the power input 205 to the welding gun 120. For example, the contactor 220 can operate to selectively electrically connect and disconnect the power input 205 and the power output 230.

[0022] As Figure 2 As shown, the time delay relay 215 can be controlled (e.g., adjustable) to selectively turn off the power output 230 by turning off the contactor 220 after a variable time period or based on any other suitable criteria. The contactor 220 can include a coil, which can be a single-phase coil. For another example, the contactor 220 can be a multi-phase contactor.

[0023] As Figure 2As shown, power output 230 can also be turned on when current is connected through current sensor input 225. Current can be connected to the surface through current sensor input 225 (e.g., through a welding gun 120 that is pressed into contact with current sensor input 225). For example, current sensor input 225 can be connected to a switch, such as a magnetic switch 122, that can be disposed in or at a control input that is connected with welding electrical control 110. Magnetic switch 122 can be any suitable type of magnetic switch that can operate with other components of system 100. For example, magnetic switch 122 can be an encoded switch, a reed switch, a transistor switch, a triac switch, or a Hall effect switch. For example, magnetic switch 122 can be configured or disposed in or on a connector 124 that can be a cable or wiring that is connected to a control input (e.g., current sensor input 225) of welding electrical control 110. Connector 124 can be a control input cable that can be connected between welding gun 120 and a control input (e.g., current sensor input 225) of welding electrical control 110 to automatically control (e.g., manage) welding power in response to current sensed by welding electrical control 110 in magnetic switch 122. Switch 122 can be configured in connector 124 that is connected to a control input (e.g., current sensor input 225) of welding electrical control 110, switch 122 can be located proximate to welding electrical control 110 relative to the length of the connection between welding gun 120 and welding electrical control 110. Locating magnetic switch 122 relatively close to welding electrical control 110 can optimize magnetic contact switch efficiency and performance due to reduced potential adverse resistance and parasitic inductive effects caused by excess cable (e.g., excess cable of connector 124 or any other suitable cable of system 100) between magnetic switch 122 and the contactor coil of contactor 220. For example, as described herein, switch 122 can move or switch from an open position to a closed position based on operation of system 100.

[0024] For example, switch 122 can be connected to current sensor input 225 and can control (e.g., automatically manage) welding power in response to current sensed by welding electrical control 110 in magnetic switch 122 (e.g., that can be connected to current sensor input 225). When a user (e.g., a welder) of system 100 continues welding, after expiration of timer 216 (e.g., as described above) of delay relay 215, switch 122 and welding electrical control 110 maintain current through contactor 220 (e.g., the coil of contactor 220), thereby maintaining welding gun 120 powered on (e.g., maintaining power on). For example, system 100 can maintain welding gun 120 powered on before expiration of timer 216, and then system 100 can continue to maintain power on while the welder continues welding. As described above, for example, welding electrical control 110 can be configured to maintain welding power on while the welder continues welding. Figure 2 As shown, power output 230 can also be turned on when current is connected through current sensor input 225. Current can be connected to the surface through current sensor input 225 (e.g., through a welding gun 120 that is pressed into contact with current sensor input 225). For example, current sensor input 225 can be connected to a switch, such as a magnetic switch 122, that can be disposed in or at a control input that is connected with welding electrical control 110. Magnetic switch 122 can be any suitable type of magnetic switch that can operate with other components of system 100. For example, magnetic switch 122 can be an encoded switch, a reed switch, a transistor switch, a triac switch, or a Hall effect switch. For example, magnetic switch 122 can be configured or disposed in or on a connector 124 that can be a cable or wiring that is connected to a control input (e.g., current sensor input 225) of welding electrical control 110. Connector 124 can be a control input cable that can be connected between welding gun 120 and a control input (e.g., current sensor input 225) of welding electrical control 110 to automatically control (e.g., manage) welding power in response to current sensed by welding electrical control 110 in magnetic switch 122. Switch 122 can be configured in connector 124 that is connected to a control input (e.g., current sensor input 225) of welding electrical control 110, switch 122 can be located proximate to welding electrical control 110 relative to the length of the connection between welding gun 120 and welding electrical control 110. Locating magnetic switch 122 relatively close to welding electrical control 110 can optimize magnetic contact switch efficiency and performance due to reduced potential adverse resistance and parasitic inductive effects caused by excess cable (e.g., excess cable of connector 124 or any other suitable cable of system 100) between magnetic switch 122 and the contactor coil of contactor 220. For example, as described herein, switch 122 can move or switch from an open position to a closed position based on operation of system 100.

[0024] For example, switch 122 can be connected to current sensor input 225 and can control (e.g., automatically manage) welding power in response to current sensed by welding electrical control 110 in magnetic switch 122 (e.g., that can be connected to current sensor input 225). When a user (e.g., a welder) of system 100 continues welding, after expiration of timer 216 (e.g., as described above) of delay relay 215, switch 122 and welding electrical control 110 maintain current through contactor 220 (e.g., the coil of contactor 220), thereby maintaining welding gun 120 powered on (e.g., maintaining power on). For example, system 100 can maintain welding gun 120 powered on before expiration of timer 216, and then system 100 can continue to maintain power on while the welder continues welding. As described above, for example, welding electrical control 110 can be configured to maintain welding power on while the welder continues welding. Figure 2Figure 1 and Figure 2 As shown, when current is maintained through contactor 220 (e.g., the coil of contactor 220), power can be transmitted from welding power source 115 to power input 205 of welding electrical control 110 via connector 112, from power input 205 to power output 230 via connector 113, and from power output 230 to welding torch 120 via connector 114. Connectors 112, 113, 114, and 124 can be any suitable connector for transmitting current, such as wiring (e.g., copper wire), cable, and / or any other suitable electrical connector.

[0025] In at least some exemplary embodiments, the time-delay relay 215 may be configured to connect welding power to the welding torch 120 when the magnetic switch 122 is closed. For example, the time-delay relay 215 may be configured to disconnect the power after a predetermined time period, such as one minute or any other desired time period (e.g., a few seconds, less than a minute, a few minutes, or any other desired time period), if the welder ceases welding. For example, the magnetic switch 122 may magnetically engage with a workpiece (e.g., workpiece 125) to generate a magnetic field. In at least some exemplary embodiments, the magnetic switch 122 may operate as a current sensor. For example, when a user (e.g., a welder) welds using the welding torch 120, the arc current through the arc 130 from the welding electrode (e.g., the welding torch 120) to the workpiece (e.g., workpiece 125) generates a magnetic field, thereby keeping the magnetic switch 122 closed. For example, while the user continues welding, even after the timer 216 of the delay relay 215 has expired (e.g., after a predetermined time period), the arc current of the arc 130 generates a magnetic field that maintains (e.g., keeps on) the current through the contactor coil of the contactor 220. When the user, such as the welder, stops welding, the arc current of the arc 130 stops, and the magnetic switch 122 opens (e.g., the magnetic switch is in the off position), cutting off the current through the contactor coil of the contactor 220 and disconnecting the power from the welding torch 120.

[0026] As an alternative to a magnetic switch, switch 122 can be any other suitable type of switch or relay that operates based on whether the welding torch 120 is being operated to generate an electric arc 130. For example, in at least some exemplary embodiments, switch 122 can be a thermal switch that operates based on whether the electric arc 130 is emitting light, an optical switch that operates based on whether the electric arc 130 is emitting light, and / or any other suitable switch that operates based on the presence or absence of the electric arc 130.

[0027] like Figure 2As shown, the time delay relay 215 can be configured to connect a welding power source (e.g., the welding power source 115) to the power output 230 when the magnetic switch 122 connected to the current sensor input 225 is closed. For example, the time delay relay 215 can be configured to disconnect power from the power output 230 after a predetermined time period and / or any other desired criteria (e.g., user input). The magnetic switch 122 connected to the current sensor input 225 can be magnetically engaged with a workpiece (e.g., the workpiece 125), thereby creating a magnetic field. For example, the magnetic switch 122 can operate as a current sensor connected to the current sensor input 225. When a user, such as a welder, is welding using the welding torch 120 connected to the power output 230, the arc current of the arc 130 to the workpiece (e.g., the workpiece 125) (e.g., through the welding electrode) creates a magnetic field such that the magnetic switch 122 that can be connected to the current sensor input 225 remains closed. For example, as the welder continues to weld, the arc current of the arc 130 creates a magnetic field that maintains current through the contactor 220 (e.g., maintains current flow through the coil of the contactor 220) even after the timer 216 of the time delay relay 215 expires, for example. When the welder stops welding, the arc current of the arc 130 stops, and the magnetic switch 122 connected to the current sensor input 225 opens (e.g., the magnetic switch is in an open position), thereby cutting off current through the contactor 220 and disconnecting current flow from the power output 230 to the welding torch 120 (e.g., based on operation of the contactor 220).

[0028] In at least some example embodiments, when a user, such as a welder, has stopped welding and the welding electrical control 110 has disconnected the power output 230 from the welding torch 120 (e.g., via operation of the contactor 220), the welder can touch the electrode of the welding torch 120 to a workpiece surface (e.g., of the workpiece 125) to be welded such that the magnetic switch 122 connected to the current sensor input 225 closes. For example, when the magnetic switch 122 connected to the current sensor input 225 closes, the time delay relay 215 reconnects the power output 230 to the welding torch 120 by energizing the contactor 220 (e.g., by energizing the coil of the contactor 220).

[0029] The welding electrical control 110 can be an alternating current welding electrical control design. For another example, the welding electrical control 110 can be a direct current welding electrical control design. For example, in a direct current example embodiment, the time delay relay 215 and the contactor 220 can be direct current components (e.g., direct current equivalent components), and the power input 205 and the transformer 210 can be single phase operating components.

[0030] The welding electrical control 110 can be connected to the welding power supply 115 and the welding torch 120 to control (e.g., automatically manage) power to the welding torch 120 in response to a sensed current in the magnetic switch 122 in the current sensor input 225. For example, in at least some example embodiments, the current of the arc 130 between the welding torch 120 and the workpiece 125 causes the magnetic switch 122 to remain closed while a user such as a welder performs a weld. For example, in at least some example embodiments, the current of the arc 130 between the welding torch 120 and the workpiece 125 is sensed by the welding electrical control 110 in the current sensor input 225, such that the welding electrical control 110 maintains the connection of the power input 205 to the welding torch 120 via the contactor 220 and the power output 230.

[0031] The system 100 (e.g., the welding electrical control 110) can include any suitable controller components for controlling the operation of the system 100. For example, as shown, the controller 235 can control the operation of the system 100. The controller 235 can be integrated into the welding electrical control 110 and / or any other suitable component of the system 100. The controller 235 can include, for example, a microprocessor logic control device or board assembly. For another example, the controller 235 can include an input / output device that allows it to connect (e.g., through wireless and / or electrical connections) to other components of the system 100. For yet another example, the controller 325 (e.g., and other components of the system 300) can communicate via Bluetooth (e.g., including the Bluetooth Low Energy or BLE standard), Wi-Fi networks, Global System for Mobile (GSM), narrowband (e.g., narrowband IoT such as LTE Catl, LTE-M, NB-IoT), networks such as 2G, 3G, 4G, 5G, and / or any other suitable communication technology. Figure 2

[0032] Figure 3 A top perspective view of an example disclosed welding electrical control 110 is shown, which can be configured to conserve welding power, reduce welding costs, and / or improve welding safety. The welding electrical control 110 can operate based on disconnecting the welding power supply of the welding torch 120 when the welding torch 120 is idle, and automatically reconnecting the power supply of the welding torch 120 in response to a sensed current in the magnetic switch 122 that magnetically engages a workpiece 125 when the unpowered welding torch 120 contacts the workpiece 125 to be welded. For example, as shown, Figure 3 The power input 205 can be connected to an output of the welding power supply 115. For example, as shown, Figure 3 ​As shown, the welding electrical control 110 can also include a transformer 210 that can be operably coupled with a time delay relay 215, a contactor 220, and a current sensor input 225 to control (e.g., manage) power supplied to a power output 230. The power output 230 can be connected to the welding torch 120. In at least some example embodiments, when an unenergized welding torch 120 connected to the power output 230 is pressed against a workpiece 125 to be welded, the welding electrical control 110 can automatically reconnect power to the power output 230 such that current is sensed by the current sensor input 225.

[0033] The example disclosed systems, devices, and methods can be used in any suitable welding application. For example, the example disclosed systems, devices, and methods can be used in any suitable application to join or attach two weldable materials.

[0034] Figure 4 An example process of the example disclosed systems and methods is depicted. In the process 400, a welder can save welding power, reduce welding costs, and / or improve welding safety using an example welding electrical control that can be configured to disconnect a welding power supply of a welding torch 120 when the welding torch 120 is idle and to automatically reconnect the power supply of the welding torch 120 in response to a sensed current in a magnetic switch 122 that is magnetically engaged with a workpiece 125 when an unenergized welding torch 120 is pressed against the workpiece 125 to be welded. For example, as Figure 4 As shown, a welder 105 (e.g., a user using a welding torch 120) can save welding power, reduce welding costs, and / or improve welding safety using a welding electrical control 110 that controls or manages power of a welding power supply 115 provided to the welding torch 120. The welder 105 can be a human user, a robotic welding system (e.g., a robotic welding arm or machine), or any other component or user that uses the welding torch 120.

[0035] In at least some example embodiments, and as shown in Figure 4 The welder 105 connects a power output of the welding power supply 115 to a power input of the welding electrical control 110 at steps 405, 410, and 415. As shown in Figure 4 The welder 105 also connects a power output of the welding electrical control 110 to the welding torch 120.

[0036] In at least some example embodiments, and as shown in Figure 4As shown, the welding electrical control 110 manages the power output to the welding torch 120 in response to a current sensed in the magnetic switch 122, which can be magnetically engaged with a workpiece 125 to be welded. For example, the welder 105 plans to use the welding torch 120 to weld the workpiece 125. For another example, the welding torch 120 can be an arc welding torch or any other suitable type of welding torch such as described herein. In at least some example embodiments, the example disclosed welding apparatus can be any suitable type of welding apparatus that utilizes electrical power.

[0037] In at least some example embodiments, and as shown in Figure 4 At step 420, the welder 105 actuates the welding torch 120 to create the arc 130 to weld the workpiece 125. For example, the welding electrical control 110 maintains the power connection of the welding power supply 115 to the welding torch 120 while the welder 105 continues to weld. The welding electrical control 110 maintains the power connection to the welding torch 120 while the welder 105 continues to weld due to the magnetic field created by the current of the arc 130 between the welding torch 120 and the workpiece 125 that keeps the magnetic switch 122 closed. In at least some example embodiments, the welder 105 can touch the welding torch 120 to a conductive surface (e.g., as described herein), which can cause the welding torch 120 to create the arc 130 (e.g., as described in the example below, the timer 216 of the delay relay 215 can start measuring or timing the predetermined time period 135).

[0038] In at least some example embodiments, and as shown in Figure 4 At step 425, the welder 105 can de-actuate the welding torch 120 and stop welding. When the welder 105 stops welding the workpiece 125, the current of the arc 130 between the welding torch 120 and the workpiece 125 stops. When the current of the arc 130 between the welding torch 120 and the workpiece 125 stops, the magnetic switch 122 opens (e.g., the magnetic switch moves to an open position) such that the welding electrical control 110 opens the power to the welding torch 120.

[0039] In at least some example embodiments, and as shown in Figure 4 After the welder 105 starts welding for the predetermined time period 135 (e.g., measured by the timer 216), the welding electrical control 110 can open the power of the welding power supply 115 from the welding torch 120 at step 430 if the welder has stopped welding. In one example, the predetermined time period 135 (e.g., of the timer 216) can be a variable time period. In at least some example embodiments, even after the predetermined time period 135 elapses, the welding electrical control 110 maintains the power connection of the welding torch 120 while the welder continues to weld due to the magnetic field created by the current of the arc 130 between the welding torch 120 and the workpiece 125 that keeps the magnetic switch 122 closed.

[0040] In at least some exemplary embodiments, and as such Figure 1 to Figure 4 As shown, at a later time, in step 435, welder 105 wishes to continue welding. For example, in step 435, welder 105 presses welding torch 120 against surface 140 to resume welding. For example, surface 140 may be a conductive surface in electrical contact with workpiece 125. For example, in step 435, in response to welder 105 pressing welding torch 120 against surface 140 (e.g., or workpiece 125), welding electrical control 110 reconnects power from welding power source 115 to welding torch 120. As another example, in step 440, welder 105 may also resume welding by pressing welding torch 120 against workpiece 125. Welder 105 may resume welding based on pressing welding torch 120 against workpiece 125 to be welded (e.g., as shown in step 440) or surface 140 (e.g., as shown in step 435), causing magnetic switch 122 to close. When the magnetic switch 122 is closed (e.g., in step 435 or step 440), the welding electrical control 110 reconnects power to the welding torch 120, and the welder 105 can continue to use the welding torch 120 to generate an arc 130 to weld the workpiece 125. When the welder 105 resumes welding and uses the welding torch 120 to generate the arc 130, the timer 216 can also begin measuring the time period 135.

[0041] Although it has been referenced Figure 2 Various embodiments have been described, but other embodiments are also possible. For example, exemplary embodiments of welding electrical control are designed to save energy, increase safety, and provide indicators for the operation of welding manufacturing equipment. Some embodiment implementations may be referred to as WELDCONE.

[0042] In at least some exemplary embodiments, the exemplary WELDCONE implementation may be an electrical control system designed to automatically disconnect and connect power to the welding equipment by touching the device on any surface, thereby working with any suitable welding equipment (e.g., electrode welding, TIG welding, and all other types of welding equipment).

[0043] In at least some exemplary embodiments, the welding electrical control design disclosed in the examples may be a standalone component that can be attached to any suitable welding machine, thereby providing the welding machine with additional capabilities.

[0044] In at least some exemplary embodiments, the welding electrical controls disclosed herein may be used and integrated into the future design of welding machines manufactured and sold globally.

[0045] In at least some example embodiments, example disclosed welding electrical controls can include: a transformer; a contactor; a time delay relay; a magnetic contact; and wiring of the components. Use of these components with any suitable welding machine can significantly save energy (e.g., cost) and improve operational safety. Using any suitable additional computing growth or other similar components, example disclosed systems, devices, and methods can provide data and / or metrics that can be used to track employee performance, equipment status, and / or any other desired metrics.

[0046] In at least some example embodiments, example disclosed systems, devices, and methods can involve: disconnecting a welding equipment power supply to a welding torch when the torch is idle, and automatically reconnecting the power supply to the torch in response to a current sensed in a magnetic switch magnetically engaged with a workpiece when the unenergized torch is tapped against the workpiece to be welded. Some example embodiments can provide an electrical control device connected between any suitable welding equipment power supply and a welding torch powered by the power supply. In various implementations, the welding torch power supply can be disconnected and reconnected by a contactor controlled by a current sensed in a magnetic switch magnetically engaged with a workpiece, resulting in welding power supply reduction to zero due to allowing the power supply connection to be substantially completely disconnected when idle, and automatic reconnection of the power supply when the torch is tapped against the workpiece to be welded.

[0047] In at least some example embodiments, example disclosed systems, devices, and methods can provide a welding power control that can be easily connected to any suitable welding equipment, thereby enabling the welding equipment to have additional capabilities, e.g., as described herein. Such ease can be a result of providing embodiments of a welding power control device that can be connected between a welding power supply and a welding torch powered by the power supply to automatically control or manage power supplied to the torch. For example, example embodiments of a welding power control device can have: a power input connectable to a welding power supply; a power output connectable to a welding torch for managing power supplied to the torch; and a control input connected to the torch and configured to reconnect the power supply to the torch when the torch is tapped against a work surface to be welded.

[0048] In at least some example embodiments, example disclosed systems, devices, and methods can provide welding power control that can be integrated into new welding equipment designs. For example, new welding equipment designs can include elements according to the present disclosure connected between welding equipment power supply elements and a welding torch powered by the power supply to automatically manage power supplied to the torch.

[0049] In at least some example embodiments, the example disclosed systems, devices, and methods can improve welding business intelligence. For example, such improved welding business intelligence can be a result of providing welding performance or productivity data while the device disconnects and reconnects the welding equipment power supply in response to welder behavior. Example welding performance or productivity data provided by various embodiment implementations can include welding productivity measurements or metrics (e.g., of a user such as a welder) measured based on the equipment disconnecting and reconnecting the welding equipment power supply in response to welder behavior, such as for example, power off time, power on time, efficiency, or number of weld cycles per unit of time. For example, a technique to measure usage time can be connected to an example disclosed contactor coil (e.g., a coil of contactor 220) in order to measure the time a welder uses the welding equipment. The welding electrical control design of some embodiments can include one or more embedded computing devices programmed and configured to capture, process, analyze, or report such welding performance or productivity data or report the data to a data storage or management application local or remote from the welding electrical control. For example, an example welding electrical control can include an embedded processor and communication link programmed and configured to report welding business intelligence, productivity, and performance data to a cloud-based management server (e.g., server 240 as shown in ​ FIG. 1). For example, computing components performing the example operations described above can be integrated into controller 235, server 240, and / or any other suitable cloud-based component. These example disclosed components of system 100 can communicate via any suitable technique (e.g., example communication techniques described herein).

[0050] In at least some example embodiments, the example disclosed systems, devices, and methods can reduce welding equipment repair parts and maintenance costs. For example, such reduced welding equipment repair parts and maintenance costs can be a result of reduced wear due to the welding equipment power supply being automatically disconnected while the welding equipment is not welding, thereby reducing the time the welding equipment remains powered on. In an illustrative example, an industrial manufacturing operation that uses welders on a shift work schedule to come and go with welding equipment that remains continuously powered on (e.g., 24 / 7), can save significant amounts of energy and cost by employing embodiments according to the present disclosure to automatically disconnect the welding equipment power supply and reconnect the power supply when the welding equipment is next pressed against the surface by a welder arriving on shift.

[0051] Various welding power control examples can achieve similar advantages consistent with the disclosure herein, where embodiments are configured to operate without a human welder. For example, a robotic welder or automated welder can implement a separate control circuit or process for welding motion activation and welding power control. Such example welding motion activation control circuits or processes can be "stateful," e.g., contextually aware in terms of the state of the welding behavior. For example, an example automated production line can stop and start welding operations via welding motion activation control. In this example, when welding is stopped, the welding power control apparatus or process of embodiments (e.g., as described herein) can automatically disconnect power to the welding torch. In this example, when the example automated production line determines that welding should be restarted, e.g., based on programming or configuration, the automated production line can be programmed or configured to use welding motion activation control to cause the welding torch to press against the work surface, thereby causing the welding power control of embodiments to automatically reconnect power. In some example embodiments, automatic control of welding power can advantageously extend to multiple interconnected robotic welding units. For example, each of a group of robotic welding units configured to perform multiple synchronized automated welding operations on a production line can be adapted with example welding power controls according to the present disclosure. In an illustrative example, the group of welding power control units can be programmed, configured, and interconnected such that power provided to all of the group of robotic welders can be disconnected a predetermined time after the last robotic welder becomes idle. Some example welding power control examples can automatically reconnect power to all members of the group of example robotic welders when one of the robotic welder units presses against a workpiece. Such a design can improve safety by decoupling welding motion activation control of the welding torch motion from welding equipment power control. For example, in such a design, welding motion activation control and power control can include separate safety interlocks. Such example designs can reduce risk based on, e.g., mitigating or substantially eliminating safety issues that can otherwise exist due to a single point of failure. In an illustrative example, a single point of failure can otherwise exist due to, e.g., a programming error or sensor failure in a system common to both welding motion activation control and power control.

[0052] In at least some example embodiments, example disclosed systems, apparatuses, and methods can include welding power control comprising: a transformer; a contactor; a time delay relay; and a magnetic contact interconnected and configured to disconnect power to a welding torch from a welding power supply when the welding torch is idle, and to automatically reconnect power to the welding torch in response to a sensed current in the magnetic contact magnetically engaged with a workpiece when the welding torch is not energized. For example, the magnetic contact can be a magnetic switch. The magnetic switch can be coupled between an example welding power control current sense control input and the welding torch. The magnetic switch can be magnetically engaged with a workpiece being welded.

[0053] In at least some example embodiments, the example disclosed systems, devices, and methods can include a welding device, which can be an arc, stick, argon arc, or other type of welding device. Another aspect of the present disclosure can be an electrical control system integrated with a new welding device. Some examples can reduce welding power costs based on automatically disconnecting power to the welding torch when the welder is not welding. Some designs can automatically reconnect power to the welding device when the welder touches the device on the surface, as the contactor is configured to connect the welding device power in response to current sensed in the magnetic contact that magnetically engages with the workpiece.

[0054] In at least some example embodiments, the example disclosed systems, devices, and methods can include a welding electrode that can be electrically connected to a power source and a workpiece by two electrical connections: a connection to ground and a positive electrical connection to the workpiece being welded.

[0055] In at least some example embodiments, when a user, such as a welder, stops welding and the welding power control disconnects the welding torch power, the welder can touch the welding torch electrode to the surface of the workpiece to be welded, causing the magnetic switch to close. For example, when the magnetic switch is closed, a time delay relay reconnects the welding torch power by energizing the contactor coil.

[0056] In at least some example embodiments, a welding power control can be provided in a device that can be connected between a welding power source and a welding torch powered by the power source, thereby controlling (e.g., managing) power supplied to the welding torch.

[0057] In at least some example embodiments, a welding power control can be provided integrated with a welding device power source to control (e.g., manage) power supplied to a welding torch that can be connected to the welding power source.

[0058] In at least some example embodiments, a welding power control can be automated based on a current-sensing magnetic switch that magnetically engages with a workpiece. For another example, an operational welding power control system can be configured to automatically control welding power based on magnetic engagement of a current-sensing magnetic switch with a workpiece to be welded.

[0059] In at least some example embodiments, an example disclosed apparatus can include a power source (e.g., a welding power source 115), a control device (e.g., a welding power control 110) connected to the power source, a welding device (e.g., a welding gun 120) selectively connected to the power source via the control device, and a switch (e.g., a switch 122) connected between the control device and the welding device. The control device can include a time delay relay that measures a predetermined time period. The switch can remain in a closed position when the predetermined time period expires and the welding device is producing a welding arc. The switch can switch from the closed position to an open position when the predetermined time period expires and the welding device stops producing the welding arc. The control device can transmit current from the power source to the welding device when the switch is closed, and the control device can block current from the power source to the welding device when the switch is in the open position. The switch can be a magnetic switch. The switch can remain in the closed position when the predetermined time period has not expired, or when the welding device is producing the welding arc at the expiration of the predetermined time period and the welding device continues to produce the welding arc without interruption after the expiration of the time period. The switch can switch from the closed position to the open position when the predetermined time period expires and the welding device has stopped producing the welding arc, or when the welding device continuously produces the welding arc after the expiration of the time period and the welding device first stops producing the welding arc after the expiration of the time period. The switch can switch from the open position to the closed position when a user contacts the welding device to a conductive surface. The time delay relay can include a timer that starts the predetermined time period when the user contacts the welding device to the conductive surface. The control device can include a contactor having a coil that is selectively energized by the switch. The switch can transmit current to the coil when the switch is in the closed position, and the coil actuates the contactor to electrically connect the power source to the welding device. The coil can remain unenergized when the switch is in the open position, and the contactor electrically disconnects the power source from the welding device. The example disclosure can also include a first electrical connector that electrically connects the power source to a power input of the control device, a second electrical connector disposed in the control device and connecting the power input to the contactor that is electrically connected to a power output of the control device, a third electrical connector that electrically connects the power output to the welding device, and a fourth electrical connector that electrically connects the welding device to the time delay relay. The time delay relay can be electrically connected to the contactor, and the switch can be disposed on the fourth electrical connector. The control device can be electrically connected between the power source and the welding device, and the time delay relay can be electrically connected between the switch and the contactor. The example disclosed apparatus can also include a web server in communication with a controller of the control device, wherein the controller transmits data to the web server.

[0060] In at least some example embodiments, the example disclosed method can include providing a power source (e.g., welding power source 115) and a welding device (e.g., welding torch 120), electrically setting a control device (e.g., welding power control 110) between the power source and the welding device, setting a switch (e.g., switch 122) between the control device and the welding device, measuring a predetermined time period with the control device, and maintaining the switch in a closed position when the predetermined time period expires and the welding device is producing a welding arc. The example disclosed method can also include switching the switch from the closed position to an open position when the predetermined time period expires and the welding device stops producing the welding arc, transmitting current from the power source to the welding device via the control device when the switch is closed, and blocking current from the power source to the welding device via the control device when the switch is in the open position. The example disclosed method can further include maintaining the closed position when the predetermined time period does not expire, or when the predetermined time period expires and the welding device is producing the welding arc and then the welding device continues to produce the welding arc after the expiration of the time period without interruption. The example disclosed method can also include switching the switch from the closed position to the open position when the predetermined time period expires and the welding device has stopped producing the welding arc, or when the welding device continuously produces the welding arc after the expiration of the time period and then the welding device stops producing the welding arc for the first time after the expiration of the time period. The example disclosed method can further include switching the switch from the open position to the closed position when a user touches the welding device to a conductive surface, and starting the timing of the predetermined time period when the user touches the welding device to the conductive surface. The example disclosed method can further include transmitting current from the switch to a contactor of the control device, actuating the contactor to electrically connect the power source to the welding device when the switch is in the closed position, and maintaining a coil of the contactor in an unenergized state when the switch is in the open position, thereby electrically disconnecting the power source from the welding device.

[0061] In at least some example embodiments, an example disclosed apparatus can include a power source (e.g., welding power source 115), a control apparatus (e.g., welding power control 110) having a power input connected to the power source via a first electrical connector, a welding apparatus (e.g., welding torch 120) selectively connected to the power source via a second electrical connector of the control apparatus, a second electrical connector connecting the power input to a contactor of the control apparatus, the contactor electrically connected to a power output of the control apparatus, a magnetic switch connected between the control apparatus and the welding apparatus, a third electrical connector electrically connecting the power output to the welding apparatus, and a fourth electrical connector electrically connecting the welding apparatus to a time delay relay of the control apparatus, the time delay relay measuring a predetermined time period. The magnetic switch can remain in a closed position when the predetermined time period expires and the welding apparatus is producing a welding arc. The magnetic switch can switch from the closed position to an open position when the predetermined time period expires and the welding apparatus stops producing the welding arc. The control apparatus can transmit current from the power source to the welding apparatus when the magnetic switch is in the closed position and block current from the power source to the welding apparatus when the magnetic switch is in the open position. The time delay relay can be electrically connected to the contactor. The magnetic switch can be disposed on the fourth electrical connector. The control apparatus can be electrically connected between the power source and the welding apparatus. The time delay relay can be electrically connected between the magnetic switch and the contactor. The welding apparatus producing the welding arc can produce a magnetic field that keeps the magnetic switch closed. When the welding apparatus stops producing the welding arc, the magnetic field stops and the magnetic switch can move from the closed position to the open position when the predetermined time period expires.

[0062] Example disclosed systems, apparatuses, and methods can reduce the cost of operating a welding apparatus, for example, by automatically disconnecting power fed to the welding apparatus when the welding apparatus is not welding. Example disclosed systems, apparatuses, and methods can reduce the workload and burden on a welder operating a welding apparatus, for example, by automatically reconnecting power fed to the welding apparatus when the welder touches the apparatus on a surface. Example disclosed systems, apparatuses, and methods can further improve welding safety, for example, by automatically disconnecting power to an idle welding apparatus to reduce the risk of fire or the risk of electric shock.

[0063] The details of various embodiments are set forth in the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

[0064] In the above summary of the application and in the detailed description of the specific embodiments and the appended claims and drawings, reference is made to particular features of the various embodiments of the application. It is to be understood that the disclosure of the embodiments of the application in this specification includes all possible combinations of these particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment or a particular claim of the application, that feature can also be used, combined, and / or used in the context of other particular aspects and embodiments of the application and in the claims of this application wherever that particular feature is possible, and generally in the application.

[0065] Although a number of embodiments of the application have been described, other embodiments of the application will become apparent to those skilled in the art from the detailed description. Numerous modifications can be made by those skilled in the art without departing from the spirit and scope of the application. Therefore, the drawings and descriptions are to be regarded as illustrative in nature and not restrictive.

[0066] It is noted that the features illustrated in the drawings are not necessarily drawn to scale, and that, unless otherwise noted, one embodiment can be used with another embodiment even though this can represent a cross-dimensionally between embodiments. Descriptions of well-known components and processing techniques can be omitted so as to not unnecessarily obscure the embodiments.

[0067] In this disclosure, various features can be described as optional, e.g., by use of the verb "may"; or, by use of any of the following phrases: "in some embodiments", "in some implementations", "in some designs", "in various embodiments", "in various implementations", "in various designs", "in illustrative examples", or "for example"; or, by use of parentheses. For brevity and readability, this disclosure does not explicitly list every permutation that can be obtained by selecting from a set of optional features. However, this disclosure will be interpreted to explicitly disclose all such permutations. For example, a system described as having three optional features can be implemented in seven different ways, namely with only one of the three possible features, with any two of the three possible features, or with all three of the three possible features.

[0068] In various embodiments, elements described herein as coupled or connected can have an enabling relationship where, for example, coupled or connected elements can be either directly connected, or connected by way of one or more other intermediate elements.

[0069] In the present disclosure, the term“any” can be understood to specify any number of the respective elements, i.e., to specify one, at least one, at least two, each, or all of the respective elements. Similarly, the term“any” can be understood to specify any collection of the respective elements, i.e., to specify one or more collections of the respective elements, including a collection of one, at least one, at least two, each, or all of the respective elements. The respective collections need not contain the same number of elements.

[0070] While various embodiments of the application have been disclosed and described in detail herein, it will be apparent to those skilled in the art that various changes in the configuration, operation and form of the application can be made without departing from the spirit and scope of the application. In particular, it will be noted that various features of the embodiments of the application, even though they can be disclosed in

[0071] The abstract is provided to comply with 37 C.F.R. § 1.72(b) to enable the reader to quickly ascertain the nature of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or the meaning of the claims.

[0072] In the present disclosure, all embodiments using“comprising” can have“consisting essentially of’ or“consisting of’ as alternatives. In the present disclosure, any method or device embodiments can be devoid of one or more processing steps or components. In the present disclosure, embodiments employing negative limitations are expressly disclosed and are considered part of the present disclosure.

[0073] Certain terminology can be used in the present disclosure, merely for the purpose of reference, and shall not be considered limiting. For example, unless otherwise noted, terms such as“up,”“down,”“left,” and“right” refer to directions in the reference drawings. Similarly, terms such as“inwardly” and“outwardly” refer to directions toward and away from, respectively, the geometric center of the device or area of interest and to the particular portion of such device or area. The references in the singular tense include the plural, and vice versa, unless otherwise specified.

[0074] The term“comprising” and its grammatical equivalents as used herein, mean that other components, ingredients, steps, or the like can optionally be present in addition to those specifically recited. Thus, for example, an embodiment that includes components A, B, and C can consist of (i.e., include only) components A, B, and C, or can include not only components A, B, and C, but also one or more other components.

[0075] Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can include one or more other steps which are carried out before, between, or after the defined steps (except where context excludes that possibility).

[0076] The term "at least" followed by a number is used herein to denote the start of a range beginning with the number followed by it. For example, "at least 1" means 1 or more than 1. The term "at most" followed by a number (which can be a range with 1 or 0 as its lower term, or a range with no lower term, depending on the variable defined) is used herein to denote the end of a range ending with the number. For example, "at most 4" means 4 or less than 4, "at most 40%" means 40% or less than 40%. In the present specification, when a range is given as "(first number) to (second number)" or "(first number) - (second number)", this means a range bounded by the second number. For example, 25-100 mm means a range with a lower bound of 25 mm and an upper bound of 100 mm.

[0077] Many suitable methods of manufacturing the individual parts of the example devices and corresponding materials are known in the art. It will be apparent to those of ordinary skill in the art, in light of the example embodiments of the present application, that one or more parts can be formed by machining, 3D printing (also known as "additive" manufacturing), CNC machining parts (also known as "subtractive" manufacturing), and injection molding. Metals, wood, thermoplastic and thermoset polymers, resins, and elastomers as described above can be used. Many suitable materials are known and available, and can be selected and mixed according to the strength and flexibility required, the preferred method of manufacturing, and the particular use, as will be apparent to those of ordinary skill in the art.

[0078] No element of an "apparatus" or "step" for performing a specified function that is implied by use of the term "means" for performing a specified function in the claims hereof should be construed as a "means plus function" clause under 35 U.S.C. § 112(f). In particular, no claim herein is intended to be interpreted to be under 35 U.S.C. § 112(f) as it applies to the term "step" for performing a specified function. Elements recited in means plus function format are intended to functionally be equivalent to the identified structure for performing the recited function.

[0079] The use of the term "first" with respect to a feature or element in a claim does not necessarily imply the existence of a second or additional such feature or element.

[0080] The phrases “connected to,” “coupled to,” and “communicating with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interactions. Two components can be functionally coupled to each other even if they are not in direct contact. The term “adjacent” refers to items that are in direct physical contact with each other, although these items are not necessarily connected together.

[0081] The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as being more preferred or advantageous than other embodiments. Although various aspects of embodiments are presented in the accompanying drawings, the drawings are not necessarily drawn to scale unless specifically indicated otherwise.

[0082] Throughout this specification, references to "embodiment" or "this embodiment" mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Therefore, as referenced throughout this specification, the cited phrases or variations thereof do not necessarily refer to the same embodiment.

[0083] Similarly, it should be understood that in the above description of the embodiments, for the purpose of simplifying this disclosure, various features are sometimes combined in a single embodiment, drawing, or description thereof. However, this method of disclosure should not be construed as reflecting an intention that any claim in this application or any claim in any application claiming priority to this application requires more features than those expressly listed in that claim. Rather, as reflected in the following claims, the inventive aspect may lie in a combination of fewer than all features in any single foregoing disclosed embodiment. Therefore, the claims corresponding to this Detailed Description are hereby expressly incorporated into this Detailed Description, each claim existing independently as a separate embodiment. This disclosure is intended to be construed as including all permutations of the independent claims and their dependent claims.

[0084] According to one embodiment of the present application, the system and method can be implemented through the use of one or more computing devices. Those of ordinary skill in the art will appreciate that an exemplary system suitable for use with embodiments in accordance with the present application can generally include one or more of a central processing unit (CPU), random access memory (RAM), storage media (e.g., a hard disk drive, solid state drive, flash memory, cloud storage), an operating system (OS), one or more application software, a display element, one or more communication means, or one or more input / output devices / means. Examples of computing devices that can be used with embodiments of the present application include, but are not limited to, a proprietary computing device, a personal computer, a mobile computing device, a tablet PC, a mini PC, a server, or any combination thereof. The term computing device can also describe two or more computing devices communicatively linked in a manner that resources are allocated and shared, such as a cluster computing device and a server farm / server farm. Those of ordinary skill in the art will appreciate that any number of computing devices can be used and embodiments of the present application are contemplated for use with any computing device.

[0085] In various embodiments, the communication means, data storage, processor, or memory can interact with other components on the computing device to enable the provision and display of various functions associated with the systems and methods detailed herein. Those of ordinary skill in the art will appreciate that there are many configurations that can be used with embodiments of the present application and embodiments of the present application are contemplated for use with any appropriate configuration.

[0086] According to one embodiment of the present application, the communication means of the system can be, for example, any means for communicating data over one or more networks or with one or more peripheral devices connected to the system. Suitable communication means can include, but are not limited to, circuitry and control systems for providing wireless connections, wired connections, cellular connections, data port connections, Bluetooth connections, or any combination thereof. Those of ordinary skill in the art will appreciate that there are many communication means that can be used with embodiments of the present application and embodiments of the present application are contemplated for use with any communication means.

[0087] Throughout this disclosure and elsewhere, block and flow diagrams illustrate methods, apparatus (i.e., systems), and computer program products. Each of the blocks of the block and flow diagrams, and combinations of the blocks of the block and flow diagrams illustrate the function and / or the achievement of a technical solution. Any and all such function (“described function”) can be performed by computer program instructions, by specialized, hardware-based computer systems, by a combination of specialized hardware and computer instructions, by a combination of general-purpose hardware and computer instructions, and so on, any and all of which can be referred to herein as “circuitry,” “module,” or “system.”

[0088] While the foregoing figures and descriptions can set forth functional aspects of the disclosed systems, it should be understood that the particular arrangements shown and described herein are not intended to limit the scope of the present disclosure, unless specifically stated or otherwise clear from the context, and that the described features can be combined in any suitable sub-combination, unless specifically stated or otherwise clear from the context.

[0089] Each element in the flow diagram illustrations can describe one step or a group of steps of a computer-implemented method. Further, each step can include one or more sub-steps. The steps have been presented in a sequence for ease of description. It should be understood that embodiments can include alternative sequences of steps that are suitable for a particular application of the technology disclosed herein. All such variations and modifications are intended to fall within the scope of the present disclosure. The description and depiction of a particular order of steps does not intend to exclude embodiments of the application having a different order of steps, unless specifically stated or otherwise clear from the context, nor does it preclude additional steps not expressly given in the description and drawings.

[0090] Traditionally, computer programs are comprised of a series of computing instructions or program instructions. It should be understood that programmable devices (i.e., computing apparatuses) can receive such computer programs and, by processing their computing instructions, produce further technical effects.

[0091] Programmable devices can include one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors, programmable devices, programmable gate arrays, programmable array logic, memory devices, application specific integrated circuits, and the like, which can be suitably employed or configured to process computer program instructions, execute computer logic, store computer data, and the like. Throughout this disclosure and elsewhere, a computer can include any and all suitable combinations of general purpose computers, special purpose computers, programmable data processing devices, processors, processor architectures, and the like.

[0092] It should be understood that a computer can include computer-readable storage media, and that the media can be internal or external, removable, replaceable, or fixed. It should also be understood that a computer can include a basic input / output system (BIOS), firmware, an operating system, a database, and the like, which can include, interface with, or support the software and hardware described herein.

[0093] Embodiments of systems as described herein are not limited to applications involving traditional computer programs or programmable devices that run them. For example, it is contemplated that embodiments of the application as claimed herein can include optical computers, quantum computers, analog computers, and the like.

[0094] Regardless of the type of computer program or computer involved, the computer program can be loaded onto a computer to produce a particular machine that can perform any and all of the illustrated functions. This special machine provides a method for performing any and all of the described functions.

[0095] Any combination of one or more computer readable medium can be utilized. The computer readable medium can be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium can be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium can be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.

[0096] Computer program instructions can be stored in a computer readable memory which can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer readable memory constitute an article of manufacture including computer readable instructions for implementing any and all of the illustrated functions.

[0097] A computer readable signal medium can include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal can take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium can be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.

[0098] Program code embodied on a computer readable medium can be transmitted using any appropriate medium, including but not limited to wireless, wired, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

[0099] The elements depicted in the flow diagrams and block diagrams throughout the drawings imply logical boundaries between elements. However, according to software or hardware engineering practices, the depicted elements can be implemented with a greater or lesser amount of physical and / or logical coupling, and with various forms, types, and strategies of interconnection than depicted in the figures.

[0100] Unless specifically stated or otherwise clear from context, the verbs "execute" and "process" are used interchangeably to indicate execution, processing, interpreting, compiling, assembling, linking, loading, any and all combinations of the foregoing, and the like. Thus, embodiments that execute or process computer program instructions, computer-executable code, or the like, can act on the instructions or code in any and all of the manners just described.

[0101] The functions and operations presented herein are not inherently related to any particular computer or other apparatus. Various general purpose systems can be used with programs in accordance with the teachings herein, or it can prove convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will be apparent from the description herein. In addition, embodiments of the present application are not described with reference to any particular programming language. It will be appreciated that a variety of programming languages can be used to implement the teachings as described herein, and any reference to a particular language is supplied for disclosure of the embodiments of the present application and to enable the claims to reach as broad a range of embodiments as the skilled person will appreciate. Embodiments of the present application are well suited to a wide variety of computer network systems over numerous topologies. Within this field, the configuration and management of large networks comprise storage devices and computers that are communicatively coupled to different computers and storage devices by a network, such as the Internet.

[0102] A number of implementations have been described. Nevertheless, it will be understood that various modifications can be made. For example, advantageous results can be achieved if steps of the disclosed techniques were performed in a different order, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. A welding electrical control device, comprising: power supply; Control device, connected to the power supply; The welding apparatus is selectively connected to the power source via the control device; as well as A switch is connected between the control device and the welding device; The control device includes a time delay relay for measuring a predetermined time period, which begins in response to a welding arc generated by the welding device when the user presses the welding device against a conductive surface. When the predetermined time period expires and the welding device is generating the welding arc, the switch remains in the closed position. When the predetermined time period expires and the welding device stops generating the welding arc, the switch switches from the closed position to the open position. and The control device transmits current from the power source to the welding device when the switch is in the closed position, and blocks the current from the power source to the welding device when the switch is in the open position.

2. The welding electrical control equipment according to claim 1, wherein the switch is a magnetic switch.

3. The welding electrical control equipment according to claim 1, wherein the switch maintains the closed position under the following conditions: When the predetermined time period has not expired; or When the predetermined time period expires, the welding device is generating the welding arc, and the welding device continues to generate the welding arc without interruption after the predetermined time period expires.

4. The welding electrical control device according to claim 1, wherein the switch switches from the closed position to the open position under the following conditions: When the predetermined time period expires and the welding device has stopped generating the welding arc; or When the welding device continuously generates the welding arc after the predetermined time period expires, and then the welding device stops generating the welding arc for the first time after the predetermined time period expires.

5. The welding electrical control device according to claim 1, wherein when the user presses the welding device against a conductive surface, the switch switches from the open position to the closed position.

6. The welding electrical control equipment according to claim 1, wherein the control device includes a contactor having a coil selectively energized by the switch.

7. The welding electrical control equipment according to claim 6, wherein: When the switch is in the closed position, the switch transmits current to the coil, and the coil actuates the contactor to electrically connect the power supply to the welding device; and When the switch is in the off position, the coil remains unenergized and the contactor electrically disconnects the power supply from the welding device.

8. The welding electrical control equipment according to claim 6, further comprising: The first electrical connector connects the power source to the power input of the control device. A second electrical connector is provided in the control device and connects the power input to the contactor, which is electrically connected to the power output of the control device. A third electrical connector connects the power output to the welding device. as well as The fourth electrical connector connects the welding device to the time delay relay.

9. The welding electrical control equipment according to claim 8, wherein: The time-delay relay is electrically connected to the contactor; and The switch is located on the fourth electrical connector.

10. The welding electrical control equipment according to claim 8, wherein: The control device is electrically connected between the power source and the welding device; and The time-delay relay is electrically connected between the switch and the contactor.

11. The welding electrical control equipment according to claim 1, further comprising a network server communicating with the controller of the control device; The controller transmits data to the network server.

12. A welding electrical control method, comprising: Provide power supply and welding equipment; A control device is electrically provided between the power source and the welding device; A switch is provided between the control device and the welding device; A predetermined time period is measured using a time delay relay of the control device, wherein the predetermined time period begins in response to the welding arc generated by the welding device when the user presses the welding device into a conductive surface; When the predetermined time period expires and the welding device is generating the welding arc, the switch is held in the closed position; When the predetermined time period expires and the welding device stops generating the welding arc, the switch is switched from the closed position to the open position; When the switch is in the closed position, current is transmitted from the power source to the welding device via the control device; as well as When the switch is in the off position, the current from the power source to the welding device is blocked via the control device.

13. The welding electrical control method according to claim 12, further comprising maintaining the closed position under the following conditions: When the predetermined time period has not expired; or When the predetermined time period expires, the welding device is generating the welding arc, and the welding device continues to generate the welding arc without interruption after the predetermined time period expires.

14. The welding electrical control method according to claim 12, further comprising switching the switch from the closed position to the open position under the following conditions: When the welding device continuously generates the welding arc after the predetermined time period expires, and then the welding device stops generating the welding arc for the first time after the predetermined time period expires.

15. The welding electrical control method according to claim 12, further comprising: When the user presses the welding device into the conductive surface, the switch is switched from the open position to the closed position.

16. The welding electrical control method according to claim 12, further comprising: When the switch is in the closed position, current is transmitted from the switch to the contactor of the control device, and the contactor is actuated to electrically connect the power supply to the welding device; as well as When the switch is in the open position, the coil of the contactor is kept in an unenergized state that electrically disconnects the power supply from the welding device.

17. A welding electrical control device, comprising: power supply; The control device has a power input connected to the power source via a first electrical connector; The welding device is selectively connected to the power source via a second electrical connector of the control device, the second electrical connector connecting the power input to a contactor of the control device, and the contactor being electrically connected to the power output of the control device; A magnetic switch is connected between the time-delay relay of the control device and the welding device. The time-delay relay measures a predetermined time period, which begins in response to the welding arc generated by the welding device when the user presses the welding device against a conductive surface. A third electrical connector connects the power output to the welding device. as well as The fourth electrical connector electrically connects the welding device to the time-delay relay of the control device; When the predetermined time period expires and the welding device is generating the welding arc, the magnetic switch remains in the closed position. When the predetermined time period expires and the welding device stops generating the welding arc, the magnetic switch switches from the closed position to the open position. and When the magnetic switch is in the closed position, the control device transmits current from the power source to the welding device, and when the magnetic switch is in the open position, the control device blocks the current from the power source to the welding device.

18. The welding electrical control equipment according to claim 17, wherein: The time-delay relay is electrically connected to the contactor; The magnetic switch is disposed on the fourth electrical connector; The control device is electrically connected between the power source and the welding device; and The time-delay relay is electrically connected between the magnetic switch and the contactor.

19. The welding electrical control equipment according to claim 17, wherein: The welding apparatus that generates the welding arc produces a magnetic field that causes the magnetic switch to close; and When the welding device stops generating the welding arc, the magnetic field stops, and when the predetermined time period expires, the magnetic switch moves from the closed position to the open position.

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