Apparatus and method for brazing

Abstract

The invention relates to an apparatus and a method for brazing. Embodiments of a brazing system are disclosed. In one embodiment, a brazing system includes a controller circuit board (controller) having a processor and memory. The system also includes a fuel gas input, a fuel gas output, an oxygen / air gas input, and an oxygen / air gas output. The system further includes a touch screen display and a foot pedal each operatively connected to the controller. The controller is configured to store a plurality of flame preset jobs in the memory. Any work may be retrieved from the controller, and the flame may be pre-circulated in response to pedaling the pedal. Each job corresponds to a series of bond brazes to be performed on the brazed assembly and includes a plurality of selectable flame presets. Each flame presetting defines a flame setting based on a flow rate of a fuel gas and a flow rate of an oxygen / air gas.

Description

[0001] This application is a divisional application of the application filed on November 28, 2018, with application number 201811448835.8 and invention title "Apparatus and Method for Brazing". Cross-references / citations of related applications are incorporated.

[0002] This U.S. patent application claims priority and benefit to U.S. Provisional Patent Application Serial No. 62 / 592,016, filed November 29, 2017, all disclosures of which are incorporated herein by reference. The entire contents of U.S. Patent No. 8,444,041, filed April 8, 2011 and published May 21, 2013, are also incorporated herein by reference. Technical Field

[0003] The embodiments of the present invention described herein generally relate to brazing systems and methods for implementing reproducible gas flow rate control using multiple gases. Background Technology

[0004] Brazing is one of the known methods of joining metal components together using a brazing filler (i.e., a metal or alloy having a lower melting point than the metals to be joined). Brazing typically involves the use of a welding torch having at least two metering needle valves controlling the flow rate and ratio of at least two welding gases. One of these gases will include a flammable fuel gas, such as LP gas, natural gas, acetylene, methane, propane, butane, hydrogen, and mixtures and combinations thereof, while the other gas will include a combustion-supporting gas, such as oxygen or air. Metering needle valves are used to manually adjust the gas flow rate before and during brazing because the gas pressure, flow rate, and / or quality can change and, in some cases, lead to quality problems. Adjustments may be required for a variety of reasons, including changes in external temperature, the total amount of gas used or the amount of gas remaining in the cylinder, and any variables affecting the gas flow rate. Furthermore, it can be very difficult for torch operators, even those with many years of experience, to set the needle valves and determine whether the gas mixture will produce a flame with an acceptable oxygen-to-fuel ratio.

[0005] In view of the aforementioned problems and disadvantages of existing brazing systems using welding torches with multiple adjustment valves, this application describes a brazing system and method to overcome these disadvantages. Summary of the Invention

[0006] Embodiments of brazing systems and methods are disclosed herein.

[0007] According to one embodiment, a single-torch brazing system is provided. The single-torch brazing system is adapted for brazing using a single brazing torch. The system includes a controller circuit board (controller) having a processor and 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, and is a non-fuel gas used by the system. The system further includes a touchscreen display operatively connected to the controller circuit board and a foot pedal operatively connected to the controller circuit board. The controller circuit board is configured to store a plurality of flame preset jobs in memory. Any of the plurality of flame preset jobs can be retrieved from the controller circuit board (e.g., via the touchscreen display) and cycled through in response to pressing the foot pedal. Each of the plurality of flame preset jobs corresponds to a series of brazing connections to be performed on a brazing assembly and includes a plurality of selectable flame presets. Each of the plurality of selectable flame presets defines a flame setting based at least on the flow rate of the fuel gas and the flow rate of the oxygen / air gas. In one embodiment, the system includes a fuel encoder knob and an oxygen / air encoder knob. By entering the setting mode of the controller circuit board via the touchscreen display and independently adjusting the flow rate of each of the fuel gas and the oxygen / air gas using the fuel encoder knob and the oxygen / air encoder knob, a flame preset among a plurality of selectable flame presets can be established in the memory of the controller circuit board. In one embodiment, the system includes a robot operatively connected to the controller circuit board via an automation interface. The controller circuit board is configured to communicate via the automation interface with a programmable logic controller of the robot holding a brazing torch to control the movement of the robot during brazing operations and to synchronize a selected flame type with the brazing position of the robot. In one embodiment, the system includes a mass flow controller operatively connected to the controller circuit board and connected between the fuel gas input and the fuel gas output. The mass flow controller is configured to at least monitor and regulate the flow rate of the fuel gas under the control of the controller circuit board. In one embodiment, the system includes a mass flow controller operatively connected to the controller circuit board and connected between the oxygen / air gas input and the oxygen / air gas output. The mass flow controller is configured to monitor and regulate the flow rate of 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 at least monitor and regulate the flow rates of the fuel gas and the oxygen / air gas to maintain a desired flame corresponding to a selected flame setting. The system includes a power board configured to supply power to at least the controller circuit board. In one embodiment, the system includes a wireless router. The wireless router is operatively 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 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 as computer-executable instructions on the external computer. The dashboard user interface is configured to process collected data from the controller circuit board by the external computer for user viewing and analysis. The collected data may relate to at least one of the following: the amount of time the brazing system is on during the brazing process, the amount of time the gas flows during the brazing process, settings associated with what the brazing system is doing and when it is doing during the brazing process, and diagnostic information.

[0008] According to one embodiment, a multi-torch brazing system is provided. The multi-torch brazing system is adapted for brazing using multiple brazing torches simultaneously. The system includes a controller circuit board having a processor and a memory. The system also includes a touchscreen display operatively 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 operatively connected to the controller circuit board and connected between the fuel gas input and the multiple fuel gas outputs. The fuel gas mass flow controller is configured to monitor and regulate the flow rate of the fuel gas at least independently 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 operatively connected to the controller circuit board and connected between the single oxygen / air gas input and the multiple oxygen / air gas outputs. The oxygen / air gas mass flow controller is configured to monitor and regulate the flow rate of the oxygen / air gas at least independently 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. By accessing the setting mode of the controller circuit board via the touchscreen display and using the fuel encoder knob and the oxygen / air encoder knob to independently adjust the fuel gas flow rate at each of the plurality of fuel gas output terminals and the oxygen / air gas flow rate at each of the plurality of oxygen / air gas output terminals, flame settings for multiple brazing torches can be established in the memory of the controller circuit board. The fuel gas mass flow controller and the oxygen / air gas mass flow controller are configured to monitor and adjust the fuel gas flow rate at each of the plurality of fuel gas output terminals and the oxygen / air gas flow rate at each of the plurality of oxygen / air gas output terminals, at least independently, under the control of the control circuit board, to simultaneously maintain different desired flames corresponding to different selected flame settings for each of the plurality of brazing torches. In one embodiment, the system further includes a first RS232 interface configured to operatively connect the controller circuit board to the fuel gas mass flow controller, and a second RS232 interface configured to operatively 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 operatively connected to an external computer. The controller board is configured to communicate wirelessly with the external computer via the wireless router for at least one of data collection and software license management. In one embodiment, the wireless router is a Wi-Fi router, and the controller board is configured to communicate wirelessly with the external computer via the Wi-Fi router. The external computer includes a dashboard user interface, which is implemented as a software application that runs as computer-executable instructions on the external computer. The dashboard user interface is configured to process collected data from the controller board by the external computer for user viewing and analysis. In one embodiment, the collected data relates to at least one of the following: the amount of time the brazing system is on during the brazing process, the amount of time gas flows during the brazing process, settings associated with what the brazing system is doing and when it is doing during the brazing process, and diagnostic information.

[0009] These and other aspects of the invention will become apparent when viewed in conjunction with the accompanying drawings, detailed description, and appended claims. Attached Figure Description

[0010] At least one embodiment of the invention may take physical form in terms of certain parts and arrangements of parts, which will be described in detail in the specification and illustrated in the drawings that form a part of this specification, and in the drawings: Figure 1 This is a side elevation view of an existing brazing system, in which flow control is achieved using a metering valve located on the welding torch; Figure 2 A configuration of a single-torch brazing system mounted on a bracket according to an embodiment of the present invention is shown; Figure 3 An embodiment of the present invention is shown. Figure 2 The single-torch brazing system is configured with various components that can be seen and accessed from the front view, inlet side view, and outlet side view of the brazing system; Figure 4 A configuration of a multi-torch brazing system mounted on a bracket according to an embodiment of the present invention is shown; Figure 5 An embodiment of the present invention is shown. Figure 4 The multi-torch brazing system configuration includes various components that can be seen and accessed from the front view, inlet side view, and outlet side view of the brazing system; Figure 6 and Figure 7 A single welding torch system according to an embodiment of the present invention is shown, illustrating a system located at... Figure 2 Various internal or external components and interfaces of a single welding torch configuration; Figure 8 and Figure 9 A multi-torch welding system according to an embodiment of the present invention is shown, illustrating a system located at... Figure 4 Various internal or external components and interfaces of a multi-torch configuration; Figure 10 An example of a soldered configuration for wireless communication with a server computer is shown; Figure 11 An embodiment of a brazing configuration that communicates with a server computer via an intermediate computer is shown; Figure 12 An embodiment of a user computer communicating with a server computer via a computer network is shown; Figures 13 to 17 An example of an exemplary screenshot provided by the dashboard user interface is shown; Figure 18A , Figure 18B , Figure 19A , Figure 19B , Figures 20 to 25 , Figure 26A and Figure 26B Showcased by Figure 4 The screenshots provided for the multi-torch configuration illustrate the process flow control; and Figure 27A , Figure 27B , Figure 28A , Figure 28B , Figure 29 , Figure 30A , Figure 30B , Figures 31 to 34 Showcased by Figure 2 The screenshot provided for the single welding torch configuration illustrates the process flow control. Detailed Implementation

[0011] Exemplary embodiments of the invention will now be described with reference to the accompanying drawings. The described exemplary embodiments are intended to aid understanding and are not intended to limit the scope in any way. Throughout the text, the same reference numerals denote the same elements.

[0012] Figure 1A prior art brazing system 100 (with a metering valve positioned on the welding torch) is shown, and includes a first gas source 105 and a second gas source 110, wherein the first gas source 105 is oxygen or air, and the second gas source 110 is a fuel including at least one of acetylene, propane, natural gas or methane, propylene, hydrogen, and butane, or blends thereof. A first gas hose 115 is connected to the first gas source 105 and to the brazing torch 120, and a second gas hose 125 is connected to the second gas source 110 and to the brazing torch 120.

[0013] In the illustrated embodiment, 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 nozzle 155. To use the conventional brazing system 100, the 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 gas mixture exiting the brazing nozzle 155. It should be understood that the gas source may be from a gas canister with a pressure regulator or from a main supply line with a pressure regulator. After ignition, the brazing torch operator adjusts the first needle valve 140 and the second needle valve 145 to respond to actual or perceived inconsistencies in the brazing flame. Furthermore, needle valve settings may be changed due to fluctuations in gas pressure and flow rate, as well as inconsistencies in the brazing joint caused by inaccurate gas mixing. As discussed above, even highly experienced torch operators encounter difficulties in setting up a flame with a consistent oxygen-to-fuel ratio.

[0014] For example, operators may find it difficult to accurately determine whether the brazing flame of the welding torch is neutral or whether it has the desired flame temperature or BTU output. Furthermore, it is very difficult for operators to produce a consistent and reproducible flame with the same flame characteristics.

[0015] Furthermore, the brazing system may include a first gas source and a second gas source, wherein the first gas source is oxygen or air, and the second gas source is a fuel, including at least one of the following: acetylene, propane, natural gas or methane, propylene, hydrogen, and butane, or blends thereof. For example, the gas source may be from a gas cylinder with a pressure regulator or from a main supply line with a pressure regulator. A first gas hose may be connected to the first gas source and to the cladding of the brazing system. A second gas hose may be connected to the second gas source and to the same cladding. In some exemplary embodiments, the cladding is made of multiple materials and is configured to meet NEMA 4X specifications.

[0016] In one embodiment, gas from a first gas source flows from the casing into a first brazing torch gas hose, and gas from a second gas source flows from the casing into a second brazing torch gas hose. The first and second brazing torch gas hoses are connected to the brazing torch. Furthermore, the brazing torch may include a handle, an operating trigger or on / off switch, a neck, and a brazing nozzle. The brazing torch also includes an internal portion in which the gases are mixed before exiting the brazing torch at the brazing nozzle. An operator activates the operating trigger on the brazing torch to ignite it.

[0017] According to one embodiment, the flow rate ratio of the first gas and the second gas, also known as the oxygen-to-fuel ratio, can be determined and / or controlled at least. Each fuel gas (including acetylene, propane, natural gas or methane, propylene, hydrogen, and butane) has a range of oxygen-to-fuel ratios that produce a consistent brazing flame each time the brazing torch is ignited by the operator. For example, the oxygen-to-fuel ratio can be set to regenerate and maximize an oxidizing flame, a neutral flame, a carburizing flame, or any flame known to those skilled in the art that has characteristics between those described above.

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

[0019] Furthermore, those skilled in the art will understand that the methods of the present invention can be practiced with other computer system configurations, including single-processor or multi-processor computer systems, microcomputers, mainframe computers, and personal computers, handheld computing devices, microprocessor-based or programmable consumer electronics, each operatively coupled to one or more associated devices. Aspects of some embodiments of the invention shown can also be practiced in a distributed computing environment in which certain tasks are performed by remote processing devices linked via a communication network. In a distributed computing environment, program modules can reside in both local and remote memory storage devices.

[0020] Computerized devices (e.g., computerized controllers) or user interfaces can utilize exemplary environments including computers to implement various aspects of some embodiments of the invention, wherein the computer includes processing units, system memory, and a system bus. The system bus couples system components, including, but not limited to, coupling system memory to the processing unit. The processing unit can be any of a variety of commercially available processors. Dual microprocessors and other multiprocessor architectures can also be employed as the processing unit.

[0021] The system bus can be any of several types of bus architectures, including memory buses or memory controllers, peripheral buses, and local buses using any of a wide variety of commercially available bus architectures. System memory can include read-only memory (ROM) and random access memory (RAM). The ROM stores the Basic Input / Output System (BIOS), which contains basic routines that, for example, help transfer information between components within the computer during startup.

[0022] Computerized devices or user interfaces may further include hard disk drives, disk drives (for example, to read from or write to removable disks), and optical disk drives (for example, to read from CD-ROMs or to read from or write to other optical media). Computerized devices or user interfaces may include at least some forms of computer-readable media. Computer-readable media can be any available media accessible to a computer. By way of example, and not limitation, computer-readable media can include computer storage media and communication media. Computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing 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 technologies, CD-ROM, Digital Universal Disc (DVD) or other magnetic storage devices, or any other media that can be used to store desired information and is accessible to the user interface.

[0023] Communication media typically contain computer-readable instructions, data structures, program modules, or other data in modulated data signals (such as carrier waves or other transport mechanisms), and include any information transmission medium. The term "modulated data signal" refers to a signal in which one or more characteristics of its characteristic set are set or altered in such a way that information in the signal is encoded. By way of example, and not limitation, communication media include wired media (such as wired networks or direct wired connections) and wireless media (such as acoustic, RF, infrared, and other wireless media). Any combination of the foregoing should also be included within the scope of computer-readable media.

[0024] Many program modules, including the operating system, one or more applications, other program modules, and program data, can be stored in the drive and RAM. The operating system in the computerized device or user interface can be any of many commercially available operating systems.

[0025] In addition, users can input commands and information into the computerized device using a keyboard and pointing devices (e.g., a mouse). Other input devices may include microphones, IR remote controls, trackballs, pen input devices, joysticks, gamepads, digitizing tablets, satellite dish receivers, scanners, etc. These and other input devices are typically connected to the processing unit via a serial port interface coupled to the system bus, but may also be connected via other interfaces, such as parallel ports, game ports, Universal Serial Bus (“USB”), IR interfaces, and / or various wireless technologies. Monitors or other types of display devices may also be connected to the system bus via interfaces (e.g., video adapters). Visual output may also be accomplished via remote display network protocols (such as Remote Desktop Protocol, VNC, X-Window systems, etc.). In addition to visual output, the computer or computerized device may also include other peripheral output devices, such as speakers, printers, etc.

[0026] A display can be used in conjunction with a user interface to present data received electronically from a processing unit. For example, a display can be a monitor such as an LCD, plasma, or CRT that displays data electronically. Alternatively or additionally, the display can present the received data in a hard copy format, such as a printer, fax machine, or plotter. The display can present data in any color and can receive data from the user interface via any wireless or hardwired protocol and / or standard.

[0027] Computerized devices can operate in a network environment using logical and / or physical connections to one or more remote computers. These remote computers can be workstations, server computers, routers, personal computers, microprocessor-based entertainment devices, peer-to-peer devices, or other common network nodes, and typically include many or all of the elements described regarding a computer. The depicted logical connections include local area networks (LANs) and wide area networks (WANs). Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet.

[0028] When used in a LAN networking environment, the computerized device connects to the local network via a network interface or adapter. When used in a WAN networking environment, the computerized device typically includes a modem, or a communication server connected to the LAN, or other devices for establishing communication over the WAN (e.g., the Internet). In a networked environment, program modules or portions thereof described with respect to the computerized device may be stored in a remote memory storage device. It should be understood that the network connections described herein are exemplary, and other means of establishing communication links between computers may be used.

[0029] The following describes some embodiments of a substantially automated brazing system. According to one embodiment of the invention, the indication of flame type (neutral, oxidizing, or carburizing) changes with variations in the oxygen-to-fuel gas ratio, determined, for example, by the controller of the brazing system. However, the controller may also take into account the type of fuel used. That is, the proportion of a first type of fuel that produces certain flame types will not be the same as the proportion of a different type of fuel. In other words, the first gas ratio will produce a neutral flame when using acetylene, but the same ratio may not produce a neutral flame when using other types of fuel gases (e.g., propane, etc.). Therefore, the controller considers both fuel type and gas ratio when determining the flame type. Similarly, for each type of fuel gas used, the range of gas ratios producing neutral, oxidizing, or carburizing flame types will be different, and therefore the controller considers these factors when determining the appropriate flame type (e.g., to indicate the flame type).

[0030] A first embodiment of a substantially automated brazing system is a single-torch brazing system configuration, which includes units supporting 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 A single welding torch unit configuration 200 mounted on a bracket 210 is shown. Figure 2 Different views of the single welding torch configuration 200 are shown, including front view 220, inlet side view 230, outlet side view 240, and rear view 250.

[0031] Figure 3The diagram illustrates various components of a single welding torch configuration 200, visible and accessible from a front view 220, an inlet side view 230, and an outlet side view 240. These components include a display touchscreen 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 components 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. Further components include a handle 226, side blinds 228, and a wall mount bracket 232. The components also include a foot pedal connector 234, an AC power input 236, and an automation interface 238.

[0032] A second embodiment of the essentially automated brazing system is a multi-torch brazing system configuration, which includes a unit supporting the operation of multiple torches (e.g., three torches) and providing each torch with a different nozzle and a different settable flow rate. The multi-torch configuration has an oxygen / air gas inlet and a fuel gas inlet, as well as multiple (e.g., three) controlled oxygen / air gas outlets and multiple (e.g., three) controlled fuel gas outlets 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, thereby reducing the cost per station. Figure 4 A multi-torch unit configuration 400 mounted on a bracket 410 is shown. Figure 4 Different views of the multi-torch configuration 400 are shown, including front view 420, inlet side view 430, outlet side view 440, and rear view 450.

[0033] Figure 5 The diagram illustrates various components of a multi-torch configuration 400 that can be seen and accessed from a front view 420, an inlet side view 430, and an outlet side view 440. These components include a display touchscreen 402, an oxygen / air encoder knob 404, a fuel encoder knob 406, an antenna 408 (e.g., a Wi-Fi antenna), a power switch 412, and a power indicator LED 414. The components also include an inlet oxygen / air line (oxygen / air gas input) 416, multiple (e.g., three) outlet oxygen / air lines (oxygen / air gas outputs) 418, an inlet fuel line (fuel gas input) 422, and multiple (e.g., three) outlet fuel lines (fuel gas outputs) 424. The components further include a handle 426, side blinds 428, a wall mount bracket 432, and an AC power input 436.

[0034] Figure 6 and Figure 7 An embodiment of a single-torch system 600 is illustrated, showing various components and interfaces integrated internally or externally with the single-torch unit configuration 200. Thus, in certain cases, terms such as “single-torch configuration 200” and “single-torch system 600” may be used herein to refer to the integrated embodiment. The single-torch system 600 includes a controller circuit board (also called a control board or controller) 260 with a memory 262 and a processor 264, a power board 270, a touchscreen display 202, a foot pedal 610, a wireless router 620 (e.g., a Wi-Fi router), a robot system 630 with 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 touchscreen display 202 and the foot pedal 610 are operatively connected to the controller circuit board 260. The power board 270 is also operatively connected to the controller circuit board 260 to provide power. In one embodiment, the controller circuit board 260 distributes power to other components, such as the touchscreen display 202. In another embodiment, the power board 270 is operatively connected to the controller circuit board 260 and other components, such as the touchscreen display 202, to provide power.

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

[0036] Figure 8 and Figure 9An embodiment of a multi-torch system 800 is illustrated, showing various components and interfaces integrated internally or externally with the multi-torch unit configuration 400. Thus, in some cases, terms such as "multi-torch configuration 400" and "multi-torch system 800" may be used herein to refer to the integrated embodiment. According to some embodiments, both the single-torch configuration 200 and the multi-torch configuration 400 use a common controller board 260, which can be configured to support either the single-torch configuration 200 or the multi-torch configuration 400. In this way, having a common controller board between the two configurations can provide economic advantages by allowing increased production capacity and reducing the cost of components on the common controller board.

[0037] The multi-torch system 800 includes a controller circuit board (also referred to 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. MFCs 480 and 490 are each configured to accommodate multiple (e.g., three) controlled output gas flows. The touchscreen display 402 is operatively connected to the controller circuit board 260. The power supply board 470 is also operatively connected to the controller circuit board 260 to provide power. In one embodiment, the controller circuit board 260 distributes power to other components, such as the touchscreen display 402. In another embodiment, the power supply board 470 is operatively connected to the controller circuit board 260 and other components, such as the touchscreen display 402, to provide power.

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

[0039] According to one embodiment, the single torch configuration 200 provides multiple (e.g., five) flame presets that can be changed and cycled via a foot pedal 610. In one embodiment, the controller circuit board 260 stores multiple flame preset jobs in its memory. Any flame preset job can be retrieved from the controller circuit board 260 (e.g., via a touchscreen display 202) and cycled in response to pressing the foot pedal 610. Each of the multiple jobs corresponds to a series of brazing connections to be performed on the brazing assembly and includes multiple selectable flame presets. Each flame preset defines the flame setting based on the flow rate of the fuel gas and the flow rate of the oxygen / air gas. Flame presets can be created for jobs in the memory of the controller circuit board 260 by entering the setting mode of the controller circuit board 260 via the touchscreen display 202. Encoder knobs 204 / 206 on the front 220 of the unit 200 are used to independently adjust the flow rates of both the oxygen / air gas and the fuel gas for the preset to create a type of flame, such as a neutral flame, an oxidizing flame, or a carburizing flame. Flame presets can be named and saved in the memory 262 of system 200 (see...). Figure 7 In one embodiment, up to 100 flame presets can be established, and these 100 flame presets can be grouped into groups or jobs with five presets, such that any preset job can be retrieved and cycled by stepping on foot pedal 610. In this way, a series of brazing connections that may each require different flame settings can be easily and conveniently adapted to be performed on the brazing assembly.

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

[0041] In one embodiment, the gas flow rate is controlled via a mass flow controller (e.g., 280 and 290 in a single-torch configuration; 480 and 490 in a multi-torch configuration). MFCs 480 and 490 are each configured to control three gas output flow rates. The single-torch configuration 200 and the multi-torch configuration 400 each include integrated software with computer-executable instructions stored in memory 262 (see [link to software]). Figure 7 and Figure 9In and configured in the common controller board 260, the processor 264 (see Figure 7 and Figure 9 The software is executed on the gas flow rate. According to one embodiment, the software automatically monitors the sensed gas flow rate and adjusts the mass flow controllers (e.g., 280 and 290 or 480 and 490) to generate and maintain (selected) (multiple) desired flames. The software is configured to respond in real time to changes in the gas flow rate.

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

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

[0044] In one embodiment (e.g., a single-torch configuration), the brazing system includes an RS485 communication port (automation interface) 238 for remote control of the brazing system via a programmable logic controller (PLC) (e.g., PLC 632 of robot system 630). The automation interface 238 is operatively connected to a controller circuit board 260. In this way, brazing can be automatically performed by robot system 630 using PLC 632 (which controls the movement of the robot holding the brazing torch), while also remotely controlling the brazing system (e.g., to retrieve different preset flame types during a robotic brazing process performed by the robot on the brazing assembly). According to one embodiment, PLC 632 effectively synchronizes the selected flame type to the robot's 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., for obtaining collected data from controller board 260) and software license management, such as... Figure 10 As shown. For example, in one embodiment of a single soldering torch configuration 200, a wireless router 620 is operatively connected to an external server computer 1000. A controller board 260, operatively connected to antenna 208, is configured to wirelessly communicate with the external server computer 1000 via the wireless router 620. In one embodiment of a multi-spinning torch configuration 400, a wireless router 820 is operatively connected to the external server computer 1000. A controller board 260, operatively connected to antenna 408, is configured to wirelessly communicate with the external server computer 1000 via the wireless router 820. According to one embodiment, the external server computer 1000 is in the field and within wireless communication range of the soldering systems 200 / 400. According to another embodiment, the soldering systems 200 / 400 may be connected to an intermediate computer system 1100 (see...). Figure 11 The intermediate computer system 1100 can then communicate wirelessly with a server computer 1000 located off-site (e.g., "in the cloud" 1110).

[0046] During data collection, data strings are wirelessly transmitted from the brazing system to a server computer 1000. According to one embodiment, the data strings may be transmitted at a specific settable time (e.g., when the brazing process is complete or at the end of a workday). According to another embodiment, the data strings may be transmitted continuously during the brazing process. The data strings include data related to, for example, the amount of time the brazing system is on during the brazing process, the amount of time gas flows during the brazing process, settings associated with what the brazing system is doing (and when) during the brazing process, and other monitoring or diagnostic information. The server computer 1000 may analyze the brazing process, or data may be extracted from the server computer 1000 by another system that may analyze the brazing process according to various embodiments. According to one embodiment, data on the server computer 1000 is presented to a user via a website interface, where a webpage resides on the server computer 1000.

[0047] According to one embodiment, for example (see Figure 12Server computer 1000 is configured to be accessed by external users and to provide collected data (e.g., collected from controller board 260) to a dashboard user interface, which allows the user to view and analyze the collected data on the user's desktop computer 1200. The user's computer 1200 can access server computer 1000 via an intermediate computer network 1210 (e.g., LAN, WAN, 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 server computer 1000, and the user simply accesses the dashboard user interface, for example, via a web browser on the user's computer 1200. The dashboard user interface is configured to process the collected data from controller board 260, allowing the user to view and analyze the collected data.

[0048] Figures 13 to 17 An example screenshot provided by the dashboard user interface is shown. Figure 13 As shown, a screenshot shows how the dashboard user interface can be accessed based on a date (see the highlighted date in the date range). The highlighted date is 10-16-17, and the date range extends from 10-15-17 to 10-19-17. Figure 13 The screenshot shows the "operation coefficient" of the brazing system, which is the percentage of time the brazing system is on or active. It shows the start operation coefficient (40%) for a start date of 10-15-17 and the end operation coefficient (50%) for an end date of 10-19-17, as well as the range of operation coefficients (40% to 50%) over the entire date range. Figure 13 The overall hourly operating factor is also shown for each of the five dates within the date range.

[0049] Figure 14 The average running coefficient for all five days within the stated date range, from 8:00 AM to 3:00 PM, is shown, along with the daily running coefficient trend for all five days. Figure 15 The hourly operating factor of the brazing system is shown for the date 10-16-17. Figure 16 The hourly operating coefficients for three different brazing systems dated 10-19-17 are shown. Figure 17 The indirect costs, labor costs, and projected savings of the brazing system are shown. Other types of screenshots provided by the dashboard user interface are also possible, according to other embodiments.

[0050] In one embodiment, the licensed brazing system cannot be operated by an operator in 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 allows the operator to use the brazing system. The license may be valid for a period of time and may require renewal for continued use. Otherwise, when the license expires, according to one embodiment, the brazing system will revert to a restricted operating mode, preventing the operator from using certain features of the brazing system.

[0051] Figures 18A to 26B Showcased by Figure 4 The screenshot provided for the multi-torch configuration illustrates the process flow control. Figure 18A and Figure 18B An embodiment of the processing flow involving the initial entry into a multi-torch configuration is shown. Figure 18A and Figure 18B The process includes setting the machine ID, configuring Wi-Fi, verifying the license, and setting the server upload time. Figure 19A and Figure 19B An embodiment of the process involving a lack of a valid license for a multi-torch configuration is shown. Figure 19A and Figure 19B The process includes renewing the license and configuring Wi-Fi. Figures 20 to 26B An embodiment involving the processing flow for a main screen, main menu, and existing licenses for multi-torch configuration is illustrated, including production mode, setup mode, and demonstration mode. For example, various processing flow features include flame settings, torch selection, flame setting selection, Wi-Fi configuration, license settings, server upload time, and display options. Other processing flow features are also possible according to other embodiments.

[0052] Figures 27A to 34 Showcased by Figure 2 The screenshot provided for the single welding torch configuration illustrates the process flow control. Figure 27A and Figure 27B An embodiment of the processing flow involving the initial entry into a single welding torch configuration is shown. Figure 27A and Figure 27B The process includes setting the machine ID, configuring Wi-Fi, verifying the license, and setting the server upload time. Figure 28A and Figure 28B An embodiment of the process involving a lack of a valid license for a single welding torch configuration is shown. Figure 28A and Figure 28B The process includes renewing the license and configuring Wi-Fi. Figures 29 to 34An embodiment involving the main screen, main menu, and current license processing flow for single torch configuration is illustrated, including production mode, setup mode, and demonstration mode. For example, various processing flow features include flame settings, job settings, torch selection, flame setting selection, Wi-Fi configuration, license settings, server upload time, and display options. Other processing flow features are also possible according to other embodiments.

[0053] While the disclosed embodiments have been shown and described in considerable detail, it is not intended to limit or in any way restrict the scope of the appended claims to such detail. Of course, it is impossible to describe every conceivable combination of components or methods for the purpose of describing various aspects of the subject matter. Therefore, this disclosure is not limited to the specific details or illustrative examples shown and described. Consequently, this disclosure is intended to include changes, modifications, and variations that fall within the scope of the appended claims and satisfy the statutory requirements of 35 U.S.SC §101. The above description of specific embodiments has been given by way of example. Based on the given disclosure, those skilled in the art will not only understand the overall inventive concept and its accompanying advantages but will also discover various apparent changes and modifications to the disclosed structures and methods. Therefore, what is sought is to cover all such changes and modifications that fall within the spirit and scope of the overall inventive concept as defined by the appended claims and their equivalents.

Claims

1. A welding torch brazing system, the system comprising: The casing includes: - Touchscreen display; - A controller circuit board within the enclosure, the controller circuit board having a processor and a memory, wherein the controller circuit board is configured by an operator to support a single-torch configuration or a multi-torch configuration, the single-torch configuration including first integrated software having first computer-executable instructions stored in the memory and configured to execute on the processor, and the multi-torch configuration including second integrated software having second computer-executable instructions stored in the memory and configured to execute on the processor. -- Wherein, the controller circuit board is operatively connected to the touchscreen display and is configured to allow a user to interact with the controller circuit board via the touchscreen display, and -- Wherein, the multi-torch configuration supports the independent setting of multiple brazing torches, and the simultaneous use of the multiple brazing torches by multiple users during multiple independent brazing processes, and wherein the casing defines an oxygen / air gas inlet and a fuel gas inlet, and at least one oxygen / air gas outlet and at least one fuel gas outlet; and - A fuel gas mass flow controller and an oxygen / air gas mass flow controller, the fuel gas mass flow controller and the oxygen / air gas mass flow controller being configured to at least monitor and regulate the flow rate of the fuel gas and the flow rate of the oxygen / air gas to maintain a desired flame corresponding to a selected flame setting.

2. The welding torch brazing system according to claim 1, wherein, The brazing system is one of a single-torch brazing system or a multi-torch brazing system, wherein the single-torch brazing system and the multi-torch brazing system have at least some controllable hardware components that are different from each other.

3. The welding torch brazing system according to claim 2, wherein, The controller circuit board is configured to control the controllable hardware components of the single-torch brazing system when the controller circuit board is installed in the single-torch brazing system and when the control circuit board is set to the single-torch configuration.

4. The welding torch brazing system according to claim 2, wherein, The controller circuit board is configured to control the controllable hardware components of the multi-torch brazing system when the controller circuit board is installed in the multi-torch brazing system and when the control circuit board is set to the multi-torch configuration.

5. The welding torch brazing system according to claim 1, wherein, The controller circuit board is configured to provide a main screen and main menu, and to support user interaction with production mode, setup mode and presentation mode at least via the touch screen display.

6. The welding torch brazing system according to claim 1 further includes a robot, the robot being operatively connected to the controller circuit board via an automation interface, wherein... The controller circuit board is configured to communicate with the programmable logic controller of the robot holding the brazing torch via the automation interface to control the movement of the robot during brazing operations and synchronize the selected flame type with the brazing position of the robot.

7. The welding torch brazing system according to claim 1, wherein, The controller circuit board provides a first processing flow for the single-torch configuration and a second processing flow for the multi-torch configuration.

8. The welding torch brazing system according to claim 7, wherein, The first processing flow includes features such as flame setting, job setting, welding torch selection, flame setting selection, WiFi configuration, software license activation, setting the server upload time for the collected data, and selecting at least one of the following display options.

9. The welding torch brazing system according to claim 7, wherein, The second processing flow includes features such as flame setting, job setting, welding torch selection, flame setting selection, WiFi configuration, software license activation, setting the server upload time for the collected data, and selecting at least one of the display options.

10. The welding torch brazing system according to claim 1, wherein, The controller circuit board is configured to control the processing flow, which includes the user initially entering the welding torch brazing system.

11. The welding torch brazing system according to claim 10, wherein, The initial access to the welding torch brazing system includes at least one of the following user settings: machine identification, WiFi configuration, software license verification, and server upload time for when the collected data collected by the controller circuit board is uploaded.

12. The welding torch brazing system according to claim 1, wherein, The controller circuit board is configured to store multiple preset flame operations in the memory. Any of the multiple preset flame operations can be retrieved from the controller circuit board. Each of the plurality of flame preset operations corresponds to a series of brazing connections to be performed on the brazing assembly, and includes a plurality of selectable flame presets. Each of the plurality of selectable flame presets is defined based on at least the flow rate of the fuel gas and the flow rate of the oxygen / air gas.

13. The welding torch brazing system according to claim 12 further includes a fuel encoder knob and an oxygen / air encoder knob, wherein, By entering the setting mode of the controller circuit board via the touchscreen display and independently adjusting the flow rate of each of the fuel gas and the oxygen / air gas using the fuel encoder knob and the oxygen / air encoder knob, a flame preset among the multiple selectable flame presets can be created in the memory of the controller circuit board.

14. The welding torch brazing system according to claim 1 further includes a wireless router and an external computer, wherein, The wireless router is operatively connected to the external computer, and the controller board is configured to communicate wirelessly with the external computer via the wireless router so that the external computer can perform at least one of data collection and software license management.

15. The welding torch brazing system according to claim 14, wherein, The wireless router is a Wi-Fi router, and the controller board is configured to communicate wirelessly with the external computer via the Wi-Fi router.

16. The welding torch brazing system according to claim 14, wherein, The external computer includes a dashboard user interface, which is implemented as a software application that runs as third computer executable instructions on the external computer. The dashboard user interface is configured to process data collected by the external computer from the controller board for user viewing and analysis.

17. The welding torch brazing system according to claim 16, wherein, The collected data relates to at least one of the following: the amount of time the welding torch brazing system is turned on during the brazing process, the amount of time the gas flows during the brazing process, settings associated with what the welding torch brazing system is doing and when it is doing during the brazing process, and diagnostic information.

18. The welding torch brazing system according to claim 16, wherein, The dashboard user interface is configured for date-based access to display the operating coefficient of the brazing torch system, wherein the operating coefficient is the percentage of time the brazing system is on or active.

19. A welding torch brazing system, comprising: The casing defines an oxygen / air gas inlet and a fuel gas inlet, as well as at least one fuel gas outlet and at least one oxygen / air gas outlet. A controller circuit board having a processor and a memory, wherein the controller circuit board is configured to support a single-torch configuration or a multi-torch configuration, the single-torch configuration including first integrated software having first computer-executable instructions stored in the memory and configured to execute on the processor, and the multi-torch configuration including second integrated software having second computer-executable instructions stored in the memory and configured to execute on the processor, and... The multi-torch configuration supports the independent setting of multiple brazing torches, and allows multiple users to simultaneously use the multiple brazing torches during multiple independent brazing processes; and A fuel gas mass flow controller and an oxygen / air gas mass flow controller are configured to monitor and regulate, at least independently, the flow rates of fuel gas at each of the at least one fuel gas output and the at least one oxygen / air gas output in the multi-torch configuration under the control of the controller circuit board, so as to simultaneously maintain different desired flames corresponding to different selected flame settings for each of the multi-brazing torches.

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