Welding Electric Control System, Device, and Method

Abstract

An apparatus is disclosed having a power source, a control device connected to the power source, a welding device selectively connected to the power source through 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 period of time. The switch maintains a closed position when the predetermined period of time expires and the welding device is generating a welding arc. The switch switches from the closed position to an open position when the predetermined period of time expires and the welding device stops generating a welding arc. The control device transmits current from the power source to the welding device when the switch is in the closed position and interrupts current from the power source to the welding device when the switch is in the open position.

Description

Technical Field

[0001] Various embodiments generally relate to control systems, devices, and methods, and more particularly, to welding electrical control systems, devices, and methods.

Background Art

[0002] Welding is the joining of materials based on a welding process that fuses or joins the materials by melting them at a high temperature. For example, an electric welder used in industrial activities such as construction, manufacturing, and repair may generate high temperatures using various energy sources, and the electric welder consumes a relatively large amount of electrical energy.

[0003] A human operator of a welder may be a skilled worker known as a welder. The welder uses various techniques that utilize a welding torch or gun powered by the welder to heat the materials to be joined and weld the materials.

[0004] During work, the welder can move the welding torch or gun between work locations or change the position of the torch or gun to approach various articles to be welded. For example, in some scenarios such as manufacturing, the welder may not be welding, but the welder may remain powered on for an extended period. When the welder is not welding, whether moving between work items or during shift changes, the welder may remain powered on. In an extended usage scenario, the welder may remain powered on throughout a scheduled shift work with different welders intermittently operating the welder on a 24-hour basis. In a business that operates a welder, significant extra costs can be incurred due to the power consumed by the welder when the welder is not actively welding or during scheduled shift changes.

[0005] Conventional welding power control devices that control the power to a welding gun based on the operating state of the welding gun have limitations. For example, some welding power control devices can reduce power when the welding machine is in an idle state, but do not cut off or completely cut off the power. Such welding power control implementations may increase the safety risk for the operator of the equipment, for example, by reducing the power to the welding machine when it is not in use but not cutting it off or completely cutting it off. In a typical example, a welding power control design that reduces the welding machine power when the welding machine is in an idle state but does not cut it off or completely cut it off can result in energy waste by the welding machine while it is continuously powered at a reduced level, for example, while the welding machine is in an idle state.

[0006] For example, U.S. Patent No. US2170861 titled "Electric Apparatus Power Saver" describes a welding power control that automatically starts and stops a welding machine at the start and restart of welding activities based on the reduction of welding machine power when the welding machine is in an idle state. However, U.S. Patent No. US2170861 does not appear to disclose, for example, completely cutting off the welding power when the welding machine is not in use, reconnecting the welding machine power when the welding machine touches the workpiece to be welded, and maintaining the welding power to the welding machine during welding by the welder based on the current flowing through the workpiece via the welding machine.

[0007] For example, U.S. Patent No. US2499635 titled "Automatic self-starting and stopping system for arc welding installations" describes a system for automatically starting and stopping welding equipment, reducing welding machine power when the welding machine is in an idle state, and enabling a welder to resume work by touching the workpiece with the welding machine, which controls welding power. However, U.S. Patent No. US2499635 does not disclose, for example, completely cutting off the welding power when the welding machine is not in use, reconnecting the welding machine power when the welding machine touches the workpiece to be welded, and maintaining the welding power to the welding machine during welding by the welder based on the current flowing through the workpiece via the welding machine.

[0008] For example, U.S. Patent No. US3748561 titled "Remote starting control circuit for welder power supply" describes a welding power control that reduces the welding machine power when the welding machine is in an idle state, remotely starts the welding machine to resume power in a predetermined time, and restarts the equipment in response to the contact between the welding machine and the workpiece. However, U.S. Patent No. US3748561 does not disclose, for example, completely cutting off the welding power when the welding machine is not in use, reconnecting the welding machine power when the welding machine touches the workpiece to be welded, and maintaining the welding power to the welding machine during welding by the welder based on the current flowing through the workpiece via the welding machine.

[0009] The disclosed exemplary systems, devices, and methods are directed to overcoming one or more of the above disadvantages and / or other deficiencies in the existing technology. SUMMARY OF THE INVENTION

[0010] In one typical embodiment, the present disclosure is directed 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 period. The switch maintains a closed position when the predetermined period has elapsed and the welding device is generating an arc. The switch switches from the closed position to the open position when the predetermined period has elapsed and the welding device stops generating 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 cuts off the current from the power source to the welding device when the switch is in the open position.

[0011] In other typical embodiments, the present disclosure is directed to a method. The method includes providing a power source and a welding device, electrically disposing a control device between the power source and the welding device, disposing a switch between the control device and the welding device, and measuring a predetermined period with the control device. The method also includes maintaining the switch in the closed position when the predetermined period has elapsed and the welding device is generating a welding arc, switching the switch from the closed position to the open position when the predetermined period has elapsed and the welding device stops generating the welding arc, transmitting current from the power source to the welding device via the control device when the switch is closed, and cutting off the current from the power source to the welding device via the control device when the switch is in the open position.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

[0013] Like reference symbols in the various drawings indicate like elements.

[0014] The disclosed exemplary systems, devices, and methods are operable welding electrical control systems configured to reduce welding power, reduce welding costs, and enhance welding safety by disconnecting welding machine power to a welding gun when the welding gun is in an idle state and automatically reconnecting power to the welding gun (e.g., in response to a current sensed by a magnetic switch magnetically engaged with a workpiece) when, for example, an unenergized welding gun is tapped against a workpiece to be welded. FIG. 1 shows an exemplary system 100. The system 100 may include a control device such as, for example, a welding electrical control device (e.g., welding electrical control apparatus 110), a power source such as, for example, a welding power source 115, and a welding device such as, for example, a welding gun 120. The welding electrical control apparatus 110 may control the operation of the welding gun 120, and the welding power source 115 may power the system 100.

[0015] The welding power source 115 may be any suitable power source for powering the system 100. For example, the welding power source 115 may be any suitable AC or DC power source for powering the 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 rectifier, and / or a DC rectifier. For example, the welding power source 115 may include a power source, an engine, a motor, a battery, and / or any other desired power component or power source.

[0016] The welding gun 120 may be any suitable component (such as a gun or a torch) for welding materials. As shown in FIG. 1, the welding gun 120 may weld the workpiece 125 via an arc 130. For example, the welding gun 120 may be a welding gun or a torch for use in plasma arc welding, gas metal arc welding, gas tungsten arc welding, shielded metal arc welding, atomic hydrogen welding, flux cored arc welding, and / or energy beam welding. The welding gun 120 may include any suitable type of gun or torch, such as a syringe-type torch or a positive-pressure torch. The welding gun 120 may include any suitable low-pressure or medium-pressure type torch or gun. In at least some exemplary embodiments, the welding gun 120 may be an oxygen-acetylene welding torch, a brazing torch, a propane torch, or a Mapp gas torch.

[0017] FIG. 2 shows a schematic diagram of an exemplary disclosed welding electrical control device 110. The welding electrical control device 110 may be configured to reduce welding power, reduce welding costs, and enhance welding safety, for example, by disconnecting welding machine power to the welding gun 120 when the welding gun 120 is in an idle state and automatically reconnecting power to the welding gun 120 when the unenergized welding gun 120 is tapped (e.g., by a user) to the workpiece 125 to be welded via the arc 130. The power may be connected and disconnected based on (e.g., in response to) a current sensed by a disclosed exemplary magnetic switch magnetically engaged with the workpiece 125.

[0018] As shown in FIG. 2, the disclosed exemplary welding electric control device 110 may include a power input 205 connected to a transformer 210. In at least some exemplary embodiments, the transformer 210 may be a three-phase step-down transformer configured to transform 480VAC to a 120VAC power source (or any other suitable level of VAC) and 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 exemplary embodiments, the transformer 210 may be a single-phase transformer. The tap voltages shown in FIG. 2 with respect to the transformer 210 are exemplary. Any other suitable voltages may be used in the transformer 210 and / or other components of the system 100. The time delay relay 215 may be any suitable switch or relay (such as an electrical switch or relay) for operating with the components of the welding electric control device 110. For example, the time delay relay 215 may be a digital solid state relay, a motor-driven relay, an analog solid state relay, or a thermostat relay. The contactor 220 may be any suitable electrical component for controlling (such as turning on and off) the disclosed exemplary circuit. For example, the contactor 220 may include a coil or an electromagnet. The contactor 220 may be, for example, a manual controller, a magnetic contactor, or a knife blade switch. The current sensor input 225 may be any suitable component for being electrically connected to and / or receiving an input from the disclosed exemplary magnetic switch. The power output 230 may be any suitable electrical component for being electrically connected to the welding gun 120 and selectively supplying or connecting power or current from the power input 205 to the welding gun 120. For example, the contactor 220 may operate to selectively electrically connect and disconnect the power input 205 and the power output 230.

[0019] As shown in FIG. 2, the time delay relay 215 can be controlled to selectively turn off the power output 230 by disconnecting the contactor 220 after a variable period or based on any other suitable criterion (e.g., it may be adjustable as such). The contactor 220 may include a coil, and the coil may be a single-phase coil. Also, for example, the contactor 220 may be a polyphase contactor.

[0020] As shown in FIG. 2, the power output 230 may turn on when current is connected via the current sensor input 225. The current may be connected via the current sensor input 225, for example, when a welder taps the surface with a welding gun 120 that can be connected to the current sensor input 225. For example, the current sensor input 225 may be connected to a switch, such as a magnetic switch, that may be arranged or positioned in a control input connection state to the welding electric control device 110. The magnetic switch 122 may be any suitable type of magnetic switch that can operate with other components of the system 100. For example, the magnetic switch 122 may be an encoded switch, a reed switch, a transistor switch, a triac switch, or a Hall effect switch. For example, the magnetic switch 122 may be configured or arranged in a connector 124 that may be a cable or wiring connected to the control input (e.g., the current sensor input 225) of the welding electric control device 110. The connector 124 may be a control input cable that can be connected between the welding gun 120 and the control input (e.g., the current sensor input 225) of the welding electric control device 110 to automatically control (e.g., regulate) the welding power in response to the current sensed by the welding electric control device 110 at the magnetic switch 122. The switch 122 that may be configured in the connector 124 connected to the control input (e.g., the current sensor input 225) of the welding electric control device 110 may be located closer to the welding electric control device 110 with respect to the length of the connection between the welding gun 120 and the welding electric control device 110. By positioning the magnetic switch 122 relatively close to the welding electric control device 110, the magnetic contact switching efficiency and performance can be optimized as a result of minimizing the potential for adverse resistance and parasitic inductance effects caused by extra cables (e.g., extra cables of the connector 124 or any other suitable cables of the system 100) between the magnetic switch 122 and the contactor coil of the contactor 220. For example, as described herein, the switch 122 may move or switch from an open position to a closed position based on the operation of the system 100.

[0021] For example, switch 122 is connected to current sensor input 225 and may control (e.g., automatically control) welding power in response to a current sensed by welding electric control device 110 in magnetic switch 122 (which may be connected to current sensor input 225). For example, while a user of system 100, such as a welder, continues welding, switch 122 and welding electric control device 110 maintain current through contactor 220 (e.g., the coil of contactor 220) and maintain power to welding gun 120 (e.g., keep the power on) after expiration of timer 216 of time delay relay 215 (as shown, for example, in FIG. 2). For example, before timer 216 expires, power to welding gun 120 is maintained by system 100, and thereafter, while the welder continues welding, power may be continuously maintained by system 100. As shown in FIGS. 1 and 2, when current is maintained through contactor 220 (e.g., the coil of contactor 220), power may be transmitted from welding power source 115, through connector 112, to power input 205 of welding electric control device 110, from power input 205, through connector 113, to power output 230, and from power output 230, through connector 114, to welding gun 120. Connectors 112, 113, 114, and 124 may be any suitable connectors for conducting current, such as, for example, wires (e.g., copper wires), cables, and / or any other suitable electrical connectors.

[0022] In at least some exemplary embodiments, the time delay relay 215 can be configured to connect welding power to the welding gun 120 when the magnetic switch 122 closes. For example, the time delay relay 215 can be configured to disconnect power after a predetermined period, such as one minute or any other desired period (e.g., a few seconds, less than one minute, several minutes, or any other desired period), when the welder stops welding. For example, the magnetic switch 122 can magnetically engage with a workpiece (e.g., the workpiece 125) to generate a magnetic field. In at least some exemplary embodiments, the magnetic switch 122 can operate as a current sensor. For example, while a user such as a welder is welding with the welding gun 120, the arc current of the arc 130 through the welding electrode (e.g., of the welding gun 120) to the workpiece (e.g., the workpiece 125) generates a magnetic field and maintains the magnetic switch 122 in a closed state. For example, while the user continues welding, even after the timer 216 of the time delay relay 215 expires (e.g., after a predetermined period has elapsed), the arc current of the arc 130 generates a magnetic field and maintains a current (e.g., keeps the on state) through the contactor coil of the contactor 220. For example, when a user such as a welder stops welding, the arc current of the arc 130 stops, the magnetic switch 122 opens (e.g., the magnetic switch reaches the open position), switches off the current through the contactor coil of the contactor 220, and disconnects power from the welding gun 120.

[0023] As an alternative to the magnetic switch, the switch 122 can be any other suitable type of switch or relay that operates based on whether the welding gun 120 is operating to generate the arc 130. For example, in at least some exemplary embodiments, the switch 122 can be a thermal switch that operates based on whether the arc 130 is emitting heat, an optical switch that operates based on whether the arc 130 is emitting light, and / or any other suitable switch that operates based on the presence or absence of the arc 130.

[0024] As shown in FIG. 2, the time delay relay 215 can be configured to connect the welding power (e.g., the welding power source 115) to the power output 230 when the magnetic switch 122 connected to the current sensor input 225 closes. For example, the time delay relay 215 can be configured to disconnect the power from the power output 230 after a predetermined period and / or any other desired criterion (e.g., user input). The magnetic switch 122 connected to the current sensor input 225 can magnetically engage with the workpiece (e.g., the work piece 125) and generate a magnetic field. For example, the magnetic switch 122 can operate as a current sensor connected to the current sensor input 225. For example, while a user such as a welder is welding with the welding gun 120 connected to the power output 230, the arc current of the arc 130 to the workpiece (e.g., through the welding electrode) generates a magnetic field and keeps the magnetic switch 122 connected to the current sensor input 225 in a closed state. For example, while the welder continues welding, the arc current of the arc 130 generates a magnetic field and maintains the current flowing through the contactor 220 (e.g., keeps the current flowing through the coil of the contactor 220 on), even after the expiration of the timer 216 of the time delay relay 215 for example. When the welder stops welding, the arc current of the arc 130 stops, the magnetic switch 122 connected to the current sensor input 225 opens (e.g., the magnetic switch assumes an open position), switches off the current flowing through the contactor 220, and disconnects the current transmission from the power output 230 to the welding gun 120 (e.g., based on the operation of the contactor 220).

[0025] In at least some exemplary embodiments, when a user, such as a welder, stops welding and the welding electrical control device 110 disconnects the power output 230 from the welding gun 120 (e.g., via the operation of the contactor 220), the welder may close the magnetic switch 122 connected to the current sensor input 225 by tapping the work surface of the object to be welded (e.g., the workpiece 125) with the electrode of the welding gun 120. For example, when the magnetic switch 122 connected to the current sensor input 225 closes, the time delay relay 215 energizes the contactor 220 (e.g., by energizing the coil of the contactor 220), thereby reconnecting the power output 230 to the welding gun 120.

[0026] The welding electrical control device 110 may be an alternating current welding electrical control design. Also, for example, the welding electrical control device 110 may be a direct current welding electrical control design. For example, in a typical direct current embodiment, the time delay relay 215 and the contactor 220 may be direct current components (e.g., direct current equivalent components), and the power input 205 and the transformer 210 may be single-phase operating components.

[0027] The welding electrical control device 110 may be connected to the welding power supply 115 and the welding gun 120 to control (e.g., automatically control) the power to the welding gun 120 in response to the current in the magnetic switch 122 sensed at the current sensor input 225. For example, in at least some exemplary embodiments, the magnetic switch 122 remains closed while a user, such as a welder, is welding due to the current of the arc 130 between the welding gun 120 and the workpiece 125. For example, in at least some exemplary embodiments, the current of the arc 130 between the welding gun 120 and the workpiece 125 is sensed by the welding electrical control device 110 at the current sensor input 225, whereby the welding electrical control device 110 maintains the connection state of the power input 205 to the welding gun 120 via the contactor 220 and the power output 230.

[0028] System 100 (e.g., welding electric control device 110) may include any suitable controller component for controlling the operation of system 100. For example, as shown in FIG. 2, controller 235 may control the operation of system 100. Controller 235 may be integrated into welding electric control device 110 and / or any other suitable component of system 100. Controller 235 may include, for example, a microprocessing logic control device or a board component. Also, for example, controller 235 may include an input / output configuration that enables it to connect to other components of system 100 (e.g., via a wireless connection and / or an electrical connection). Also, for example, controller 325 (and other components of system 300) may communicate via a network such as Bluetooth (including, for example, Bluetooth Low Energy or BLE standard), Wi-Fi network, Global System for Mobile (GSM), narrowband (e.g., narrowband IoT such as LTE Cat1, LTE-M, NB-IoT, etc.), for example, 2G, 3G, 4G, 5G, and / or any other suitable communication technology.

[0029] FIG. 3 shows a top perspective view of an exemplary welding electrical control device 110 that can be configured to reduce welding power, reduce welding costs, and / or enhance welding safety. The welding electrical control device 110 cuts off the welding machine power to the welding gun 120 when the welding gun 120 is in an idle state, and when the non-powered welding gun 120 is tapped on the workpiece 125 to be welded, it operates based on automatically reconnecting power to the welding gun 120 in response to the current sensed at the magnetic switch 122 magnetically engaged with the workpiece 125. For example, as shown in FIG. 3, the exemplary welding electrical control device 110 may include a power input 205 that can be attached (via any suitable fastener such as a screw-type mechanical fastener) to the housing of the welding electrical control device 110. The power input 205 can be connected to the output of the welding power source 115. The welding electrical control device 110 may also include a transformer 210 that can be operably coupled to a time delay relay 215, a contactor 220, and a current sensor input 225 to control (e.g., regulate) the power supplied to the electrical output 230. The electrical output 230 can be connected to the welding gun 120. In at least some exemplary embodiments, the welding electrical control device 110 may automatically reconnect power to the electrical output 230 when a current is sensed via the current sensor input 225 when the non-powered welding gun 120 connected to the electrical output 230 is tapped again on the workpiece 125 to be welded.

[0030] The disclosed exemplary systems, devices, and methods can be used in any suitable application related to welding. For example, the disclosed exemplary systems, devices, and methods can be used in any suitable application for joining or adhering two weldable materials.

[0031] Figure 4 shows a typical process of a disclosed exemplary system and method. In process 400, a welder may cut off the welding electrical power to welding gun 120 when the welding gun 120 is in an idle state, and when the de-energized welding gun 120 is tapped against the workpiece 125 to be welded, automatically reconnect power to the welding gun 120 in response to the current sensed at the magnetic switch 122 magnetically engaged with the workpiece 125, using a typical welding electrical control device that may be configured to reduce welding power, reduce welding costs, and / or enhance welding safety. For example, as shown in Figure 4, a welder 105 (e.g., a user using the welding gun 120) may use a welding electrical control device 110 to control or regulate the power of the welding power source 115 supplied to the welding gun 120 to reduce welding power, reduce welding costs, and / or enhance welding safety. The welder 105 may be a human user, a robotic welding system (e.g., a robotic welding arm or machine), or any other assembly or user using the welding gun 120.

[0032] In at least some exemplary embodiments, as shown in Figure 4, in steps 405, 410, and 415, the welder 105 connects the power output of the welding power source 115 to the power input of the welding electrical control device 110. As shown in Figure 4, the welder 105 also connects the power output of the welding electrical control device 110 to the welding gun 120.

[0033] In at least some exemplary embodiments, as shown in Figure 4, the welding electrical control device 110 controls the power output to the welding gun 120 in response to the current sensed at the magnetic switch 122 that may be magnetically engaged with the workpiece 125 to be welded. For example, the welder 105 plans to weld the workpiece 125 using the welding gun 120. Also for example, the welding gun 120 may be an arc welding gun or any other suitable type of welding gun as described herein, for example. In at least some exemplary embodiments, the disclosed exemplary welding machine may be any suitable type of welding machine that uses power.

[0034] In at least some exemplary embodiments, as shown in FIG. 4, in step 420, the welder 105 activates the welding gun 120 to generate an arc 130 for welding the workpiece 125. For example, the welding electric control device 110 maintains the power connection of the welding power source 115 to the welding gun 120 while the welder 105 continues welding. The welding electric control device 110 maintains the power connection to the welding gun 120 while the welder 105 continues welding by generating a magnetic field that maintains the arc 130 current between the welding gun 120 and the workpiece 125 in a closed state of the magnetic switch 122. In at least some exemplary embodiments, the welder 105 may tap a conductive surface (such as described herein) with the welding gun 120, whereby the welding gun 120 may generate an arc 130 (for example, the timer 216 of the time delay relay 215 may start measuring or timing a predetermined period 135 as in the example described below).

[0035] In at least some exemplary embodiments, as shown in FIG. 4, in step 425, the welder 105 stops the welding gun 120 to stop welding. When the welder 105 stops welding the workpiece 125, the arc 130 current between the welding gun 120 and the workpiece 125 stops. When the arc 130 current between the welding gun 120 and the workpiece 125 stops, the magnetic switch 122 opens (for example, the magnetic switch moves to the open position), whereby the welding electric control device 110 disconnects the power to the welding gun 120.

[0036] In at least some exemplary embodiments, as shown in FIG. 4, if the welder 105 stops welding after a predetermined period 135 (e.g., measured by timer 216) since starting the welding, at step 430, the welding electric control device 110 may disconnect the power of the welding power source 115 from the welding gun 120. In one example, the predetermined period 135 (e.g., of timer 216) may be a variable period. In at least some exemplary embodiments, even after the expiration of the predetermined period 135, an arc 130 current between the welding gun 120 and the workpiece 125 generates a magnetic field, and the magnetic switch 122 is maintained in a closed state, so that while the welder continues welding, the welding electric control device 110 maintains the electrical connection to the welding gun 120.

[0037] In at least some exemplary embodiments, as shown in FIG. 4, some time later at step 435, the welder 105 desires to continue welding. For example, at step 435, the welder 105 taps the surface 140 with the welding gun 120 to resume welding. For example, the surface 140 may be a conductive surface that is in electrical contact with the workpiece 125. For example, at step 435, in response to the welder 105 tapping the surface 140 (or the workpiece 125) with the welding gun 120, the welding electrical control device 110 reconnects the power of the welding power source 115 to the welding gun 120. Also for example, the welder 105 may resume welding by tapping the workpiece 125 with the welding gun 120, for example at step 440. The welder 105 may resume welding based on closing the magnetic switch 122 by tapping the workpiece 125 to be welded (as shown, for example, in step 440) or the surface 140 (as shown, for example, in step 435) with the welding gun 120. When the magnetic switch 122 closes (for example, at step 435 or step 440), the welding electrical control device 110 reconnects power to the welding gun 120, and the welder 105 may resume using the welding gun 120 to generate an arc 130 to weld the workpiece 125. Also, the timer 216 may start measuring the period 135 when the welder 105 resumes welding and generates an arc 130 using the welding gun 120.

[0038] Although various embodiments have been described with reference to FIGS. 1 - 4, other embodiments are possible. For example, an exemplary embodiment design of a welding electrical control device may conserve energy, improve safety, and provide metrics regarding the operation of a welding manufacturing machine. Implementations of some embodiments may be referred to as WELDCONE.

[0039] In at least some exemplary embodiments, a typical WELDCONE implementation may be an electrical control system designed to work with any suitable welding machine (e.g., shielded arc welding machine, TIG welding machine, and all other types of welding machines) by automatically disconnecting and reconnecting power to the welder simply by tapping any surface with a device.

[0040] In at least some exemplary embodiments, the design of the disclosed typical welding electrical control device may be a stand-alone component that can be attached to any suitable welding machine to provide additional functionality to that welding machine.

[0041] In at least some exemplary embodiments, the disclosed typical welding electrical control device can be used and incorporated in future welding machine designs that are manufactured and sold worldwide.

[0042] In at least some exemplary embodiments, the disclosed typical welding electrical control device may include a transformer, contactors, time-delay relays, magnetic contactors, and wiring for connecting the components. By using these components with any suitable welding machine, significant energy (e.g., cost) savings and improved operational safety can be achieved. Using any suitable additional computing device or other similar components, the disclosed typical systems, devices, and methods may provide data and / or metrics that can be used to track the work habits of employees, the status of equipment, and / or any other desired metric.

[0043] In at least some exemplary embodiments, the disclosed exemplary systems, apparatuses, and methods include disconnecting welding machine power to a welding gun when the welding gun is in an idle state, and automatically reconnecting power to the welding gun in response to a current sensed by a magnetic switch magnetically engaged with a workpiece when the powered-off welding gun is tapped against the workpiece to be welded. Some exemplary embodiments may provide an electrical control device connected between any suitable welding machine power source and a welding gun powered by the power source. In various implementations, the welding gun power can be disconnected and reconnected via a contactor controlled by a current sensed by a magnetic switch magnetically engaged with the workpiece, thereby reducing the welding power to zero by allowing for a nearly complete power cut-off during the idle state and automatically reconnecting the power when the welding gun is tapped against the workpiece to be welded.

[0044] In at least some exemplary embodiments, the disclosed exemplary systems, apparatuses, and methods provide a welding power control device that can be easily connected to any suitable welding machine, thereby adapting the welding machine to have additional features, such as those described herein. This can be facilitated by providing a welding power control device embodiment that can be connected between a welding power source and a welding gun powered by the welding power source to automatically control or regulate the power supplied to the welding gun. For example, a typical embodiment of a welding power control device may have one power input connectable to a welding power source, one power output connectable to a welding gun for controlling the power supplied to the welding gun, and one control input connected to the welding gun and configured to reconnect power to the welding gun when the welding gun is tapped against the workpiece surface to be welded.

[0045] In at least some exemplary embodiments, the disclosed exemplary systems, apparatuses, and methods may provide a welding power control device that can be integrated into a new welder design. For example, the new welder design may include an element connected between a welder power source element and a welding gun powered by the power source to automatically control the power supplied to the welding gun according to the present disclosure.

[0046] In at least some exemplary embodiments, the disclosed exemplary systems, devices, and methods can improve welding business intelligence. For example, such improved welding business intelligence can be obtained as a result of providing welding performance or productivity data captured when a device disconnects and reconnects a welding power source in response to a welder's activities. Exemplary welding performance or productivity data provided by various embodiment implementations may include welding productivity measurements or metrics (such as those of a user, such as a welder), such as power-off time, power-on time, efficiency, or number of welding cycles per unit time, measured based on the disconnection and reconnection of the welding power source of a device in response to a welder's activities. For example, to facilitate measuring the time a welder uses a welding machine, a technique for measuring usage time can be connected to an exemplary contactor coil (such as the coil of contactor 220) disclosed. The design of the welding electrical control device in some embodiments may include one or more embedded computing devices programmed and configured to capture, process, analyze, or report such welding performance or productivity data to a data storage or management application local or remote to the welding electrical control device. For example, an exemplary welding electrical control device may include an embedded processor and a communication link programmed and configured to report welding business intelligence, productivity, and performance data to a cloud-based management server (such as server 240 shown in FIG. 2). For example, computing components performing the exemplary operations described above can be integrated into controller 235, server 240, and / or any other suitable cloud-based component. The components of these exemplary systems 100 disclosed may communicate via any suitable technique, such as the exemplary communication techniques described herein.

[0047] In at least some exemplary embodiments, the disclosed exemplary systems, apparatuses, and methods can reduce welder repair parts and maintenance costs. For example, such a reduction in welder repair parts and maintenance costs may be the result of reduced wear and tear based on reducing the time the welder is powered by automatically cutting off the power when the welder is not in use. In an exemplary case, in an industrial production operation that uses a welder that is continuously powered (e.g., powered 24 hours a day) for welders to come and go on an alternating shift schedule, by utilizing the embodiments according to the present disclosure to automatically cut off the welder power and then reconnect the power when the next alternating welder taps the surface with the welder, significant energy and cost savings can be achieved.

[0048] Examples of various welding power controls may be implemented in a configuration that operates even in the absence of a human welder and may achieve similar benefits in line with those disclosed herein. For example, a robotic welder or an automatic welding machine may implement an individual control circuit or process for the operation of the welding operation and the control of the welding power. Such a typical welding operation control circuit or process may be "stateful", i.e., context-aware with respect to the state of the welding activity. For example, a typical automated production line may stop and start the welding operation via the welding operation control. In this example, when welding stops, an embodiment of a welding power control device or process (such as described herein) may automatically cut off the power to the welding gun. In this example, for instance, based on programming or configuration, when a typical automated production line determines that welding should resume, the automated production line may be programmed or configured to automatically reconnect power to an embodiment of the welding power control device by tapping the work surface with the welding gun using the welding operation control device. In some typical embodiments, the automatic control of the welding power may advantageously be extended to a plurality of interconnected robotic welding units. For example, each of a group of robotic welding units configured to perform various synchronized automatic welding operations on a production line may be adapted with a typical welding power control device according to the present disclosure. In a typical example, a group of welding power control units may be programmed, configured, and interconnected such that power may be cut off to all of the robotic welder group for a predetermined time after the last robotic welder becomes idle. In some examples of typical welding power control devices, when one of the robotic welder units taps the workpiece, power may be automatically reconnected to all members of the robotic welder group embodiment. Such a design may improve safety by separating the control of the movement of the welding gun for the welding operation from the welding machine power control. For example, in such a design, the welding operation control and the power control may include individual safety interlocks. Such a typical design may reduce risks based on, for example, mitigating or substantially eliminating safety issues that may arise from a single failure.In a typical example, a single defect may exist, for example, as a result of a programming error or a sensor failure in a system common to both welding operation actuation control and power control.

[0049] In at least some typical embodiments, the disclosed typical systems, devices, and methods are interconnected and configured to disconnect the welding machine power to the welding gun when the welding gun is in an idle state, and automatically reconnect power to the welding gun in response to a current sensed by a magnetic switch magnetically engaged with the workpiece when the de-energized welding gun is tapped on the surface, and include a welding power control device comprising a transformer, a contactor, a time delay relay, and a magnetic contact. The magnetic contact may be, for example, a magnetic switch. The magnetic switch may be coupled between the current sensing control input of a typical welding power control device and the welding gun. The magnetic switch may be magnetically engaged with the workpiece during welding.

[0050] In at least some typical embodiments, the disclosed typical systems, devices, and methods may include a welding machine, which may be, for example, an arc welder, a shielded metal arc welder, a TIG welder, or other types of welding machines. Other aspects of the present disclosure may be an electrical control system integrated into a new welding machine. Some examples may reduce welding power costs based on automatically disconnecting power to the gun when the welder is not welding. Some designs may automatically reconnect power to the welding machine by a contactor configured to connect welding machine power in response to a current sensed by a magnetic contact magnetically engaged with the workpiece when the welder taps the surface with the device.

[0051] In at least some typical embodiments, the disclosed typical systems, devices, and methods may include welding electrodes that can be electrically connected to the power source and the workpiece by two electrical connections, an electrical connection to electrical ground and a positive electrical connection to the workpiece during welding.

[0052] In at least some exemplary embodiments, when a user, such as a welder, stops welding and the welding electric control device cuts off the power of the welding gun, the welder may tap the welding gun electrode on the workpiece to be welded and close the magnetic switch. For example, when the magnetic switch is closed, the time delay relay energizes the contactor coil to reconnect power to the welding gun.

[0053] In at least some exemplary embodiments, the welding power control device may control (e.g., regulate) the power supplied to the welding gun by being provided within a device connectable between the welding power source and the welding gun powered by the power source.

[0054] In at least some exemplary embodiments, the welding power control device may be provided to be integrated into the welding machine power source to control (e.g., regulate) the power supplied to a welding gun connectable to the welding power source.

[0055] In at least some exemplary embodiments, the welding electric control device may be automated based on a current sensing magnetic switch magnetically engaged with the workpiece. Also, for example, an operable welding electric control system may be configured to automatically control the welding power based on magnetically engaging a current sensing magnetic switch with the workpiece to be welded.

[0056] In at least some exemplary embodiments, the exemplary apparatus disclosed may include a power source (e.g., welding power source 115), a control device connected to the power source (e.g., welding electric control device 110), a welding device selectively connected to the power source via the control device (e.g., welding gun 120), and a switch (e.g., switch 122) connected between the control device and the welding device. The control device may include a time delay relay that measures a predetermined period. The switch may maintain a closed position when the predetermined period has elapsed and the welding device is generating a welding arc. The switch may switch from a closed position to an open position when the predetermined period has elapsed and the welding device stops generating a welding arc. The control device may transmit current from the power source to the welding device when the switch is closed and cut off the current from the power source to the welding device when the switch is in the open position. The switch may be a magnetic switch. The switch may maintain a closed position when the predetermined period has not elapsed, or when the welding device is generating a welding arc at the expiration of the predetermined period, and when the welding device continuously generates a welding arc without interruption after the expiration of the period. The switch may switch from a closed position to an open position when the predetermined period has elapsed and the welding device has stopped generating a welding arc, or when the welding device has continuously generated a welding arc after the expiration of the period and then the welding device stops generating a welding arc for the first time after the expiration of the period. The switch may switch from an open position to a closed position when the user taps the welding device on a conductive surface. The time delay relay may include a timer that starts a predetermined period when the user taps a conductive surface with the welding device. The control device may include a contactor having a coil selectively energized by the switch. When the switch is in the closed position, the switch may transmit current to the coil, thereby actuating the contactor and electrically connecting the power source to the welding device. When the switch is in the open position, the coil may be maintained in a non-energized state, and the contactor electrically disconnects the power source from the welding device.The disclosed typical example may further include a first electrical connector that electrically connects a power source to the power input of the control device, a second electrical connector that is disposed within the control device and connects the power input to a contactor that is electrically connected to the 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 a time-delay relay. The time-delay relay is electrically connected to the contactor, and the switch may be disposed at the fourth electrical connector. The control device is electrically connected between the power source and the welding device, and the time-delay relay may be electrically connected between the switch and the contactor. The disclosed typical device may further include a network server that communicates with the controller of the control device, and the controller transfers data to the network server.

[0057] In at least some exemplary embodiments, an exemplary method disclosed may include providing a power source (e.g., welding power source 115) and a welding device (e.g., welding gun 120), electrically disposing a control device (e.g., welding electric control device 110) between the power source and the welding device, disposing a switch (e.g., switch 122) between the control device and the welding device, measuring a predetermined period by the control device, and maintaining the switch in a closed position when the predetermined period has elapsed and the welding device is generating a welding arc. The exemplary method disclosed may also include switching the switch from the closed position to the open position when the predetermined period has elapsed and the welding device stops generating the welding arc, transmitting current from the power source to the welding device through the control device when the switch is closed, and interrupting the current from the power source to the welding device through the control device when the switch is in the open position. The exemplary method disclosed may further include maintaining the closed position when the predetermined period has not elapsed, or maintaining the closed position when the welding device is generating a welding arc at the end of the predetermined period and continuously generating the welding arc without interruption after the end of the period. Additionally, the exemplary method disclosed may include switching the switch from the closed position to the open position when the predetermined period has elapsed and the welding device stops generating the welding arc, or when the welding device is continuously generating the welding arc after the end of the period and then stops generating the welding arc for the first time after the end of the period. The exemplary method disclosed may include switching the switch from the open position to the closed position when the user taps a conductive surface with the welding device, and starting the timing of the predetermined period when the user taps the conductive surface with the welding device. The exemplary method disclosed may 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 the coil of the contactor de-energized and electrically disconnecting the power source from the welding device when the switch is in the open position.

[0058] In at least some exemplary embodiments, the exemplary apparatus disclosed may include a power source (e.g., welding power source 115), a control device (e.g., welding electric control device 110) having a power input connected to the power source via a first electrical connector, a welding device (e.g., welding gun 120) selectively connected to the power source via a second electrical connector of the control device, a second electrical connector connecting the power input to a contactor of the control device electrically connected to the power output of the control device, a magnetic switch connected between the control device and the welding device, a third electrical connector electrically connecting the power output to the welding device, and a fourth electrical connector electrically connecting the welding device to a time delay relay of the control device that measures a predetermined period. The magnetic switch may maintain a closed position when the predetermined period has elapsed and the welding device is generating a welding arc. The magnetic switch may switch from the closed position to the open position when the predetermined period has elapsed and the welding device stops generating the welding arc. The control device may transmit current from the power source to the welding device when the magnetic switch is in the closed position and interrupt the current from the power source to the welding device when the magnetic switch is in the open position. The time delay relay may be electrically connected to the contactor. The magnetic switch may be disposed at the fourth electrical connector. The control device may be electrically connected between the power source and the welding device. The time delay relay may be electrically connected between the magnetic switch and the contactor. The welding device generating the welding arc may generate a magnetic field that closes the magnetic switch. When the welding device stops generating the welding arc, the magnetic field stops and at the expiration of the predetermined period, the magnetic switch may move from the closed position to the open position.

[0059] The disclosed exemplary systems, devices, and methods can reduce the cost of operating a welding machine, for example, by automatically disconnecting power to the welding machine when the welding machine is not in use. The disclosed exemplary systems, devices, and methods can reduce the labor and burden on the welder in operating the welding machine, for example, by automatically reconnecting power to the welding machine when the welder taps the surface with the welding machine. The disclosed exemplary systems, devices, and methods can further enhance the safety of welding, for example, by automatically cutting off power to put the welding machine in an idle state, thereby reducing the risk of ignition and electric shock.

[0060] Details of various embodiments are described in the accompanying drawings and this description. Other features and advantages will be apparent from this description and the drawings, and from the claims.

[0061] In the above summary and this detailed description, and in the claims that follow and the accompanying drawings, specific features of various embodiments of the invention are referenced. It should be understood that the disclosure of embodiments of the invention herein includes all possible combinations of such specific features. For example, if a specific feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can, to the extent possible, be combined with other specific aspects and embodiments of the invention, and / or in that context, and generally in the invention.

[0062] Although numerous embodiments are disclosed, other embodiments of the invention will be apparent to those skilled in the art from this detailed description. The invention is capable of numerous modifications in various obvious aspects, all of which do not depart from the spirit and scope of the invention. Accordingly, the drawings and description are to be regarded as illustrative rather than restrictive in nature.

[0063] It should be noted that the features shown in the drawings are not necessarily drawn to a fixed scale, and the features of one embodiment may be used with other embodiments as recognized by those skilled in the art even if not clearly described in this specification. Descriptions of well-known components and processing techniques may be omitted to avoid unnecessarily obscuring the embodiments.

[0064] In the present disclosure, various features may be described as optional, for example, by the use of the verb "may", or by the use of any of the expressions "in some embodiments", "in some implementations", "in some designs", "in various embodiments", "in various implementations", "in various designs", "in typical examples", or "for example", or by the use of parentheses. For the sake of brevity and readability, the present disclosure does not describe every variation that may be omitted by selecting from a set of optional features. However, the present disclosure should be construed as disclosing all such variations explicitly. For example, a system described as having three optional features may be embodied in seven different ways, i.e., having only one of the three possible features, any two of the three possible features, or all three of the three possible features.

[0065] In various embodiments, elements described as being coupled or connected herein may have an effective relationship that can be realized by direct or indirect connection with one or more other elements intervening.

[0066] In the present disclosure, the term "any" can be understood to indicate any number of each of the elements, i.e., one, at least one, at least two, each, or all of each of the elements. Similarly, the term "any" can be understood to indicate any set (s) of each of the elements, i.e., one or more sets of each of the elements, and the set may comprise one, at least one, at least two, each, or all of each of the elements. Each set does not necessarily have the same number of elements.

[0067] Although various embodiments of the present invention are disclosed and described in detail herein, it will be apparent to those skilled in the art that various changes can be made to the configuration, operation, and form of the present invention without departing from the spirit and scope of the present invention. In particular, it should be noted that each feature of the embodiments of the present invention can be combined in any configuration, except when it is clear to those skilled in the art that it is meaningless even when only the combination with other features of the embodiments of the present invention is disclosed. Similarly, the use of the singular and plural forms is merely for the purpose of explanation and should not be construed as limiting.

[0068] The abstract is provided in accordance with 37 C.F.R. 1. Paragraph 72(b) to enable the reader to quickly confirm the essence of the technical disclosure and is presented with the understanding that it is not used to interpret or limit the scope or intent of the claims.

[0069] In the present disclosure, all embodiments in which "comprising" is used may alternatively have "consisting essentially of" or "consisting of". In the present disclosure, an embodiment of any method or apparatus may be lacking one or more process steps or components. In the present disclosure, embodiments using negative limitations are clearly disclosed and are considered part of the present disclosure.

[0070] Certain terms and their derivatives are used in the present disclosure for reference purposes for convenience and are not limiting. For example, words such as "above", "below", "left", and "right" refer to the directions in the drawings in which they are mentioned, unless otherwise specified. Similarly, words such as "inward" and "outward" refer to the directions toward and away from the geometric center of the device or area and the specified part, respectively. Unless otherwise specified, a reference to the singular includes the plural and vice versa.

[0071] The term "comprising" and its grammatical synonyms are used herein to intentionally mean that other components, elements, steps are optionally present among others. For example, an embodiment "comprising" components A, B, and C can consist of (i.e., only include) components A, B, and C, or may include one or more other components in addition to components A, B, and C.

[0072] When a method comprising two or more defined steps is referred to herein, the defined steps can be performed in any order (except when precluded by context) or simultaneously, and the method can include one or more other steps performed either before any of the defined steps, between two of the defined steps, or after all of the defined steps (except when precluded by context).

[0073] The term "at least" before a number is used herein to denote the start of a range (which may be a range with an upper limit depending on the variable being defined or a range without an upper limit) starting from that number. For example, "at least 1" means 1 or more. The term "up to" before a number (which may be a range with a lower limit of 1 or 0 depending on the variable being defined or a range without a lower limit). For example, "up to 4" means 4 or less than 4, and "up to 40%" means 40% or less than 40%. In this specification, a range is described as "(a first number) to (a second number)" or "(a first number)~(a second number)", which means a range with the second number as the limit. For example, 25~100mm means a range with a lower limit of 25mm and an upper limit of 100mm.

[0074] A number of suitable methods and corresponding materials for making each of the individual parts of the apparatus embodiments are known in the art. According to embodiments of the present invention, one or more of the parts can be formed by machining, 3D printing (also known as "additive" manufacturing), CNC machined parts (also known as "subtractive" manufacturing), and injection molding, as will be apparent to those skilled in the art. Metals, woods, thermoplastics and thermosetting polymers, resins and elastomers as may be described above in this specification can be used. A number of suitable materials are known and available and can be selected and mixed depending on the desired strength and flexibility, suitable manufacturing methods and specific applications, as will be apparent to those skilled in the art.

[0075] Any element in a claim of this specification that does not expressly recite a "means for" performing a particular function or a "step for" performing a particular function shall not be construed as falling under the "means" or "step" clauses as set forth in 35 U.S.C. 112(f). In particular, the use of "step of" in the claims of this specification is not intended to invoke the provisions of 35 U.S.C. 112(f). Elements recited in means-plus-function format are intended to be construed in accordance with 35 U.S.C. 112(f).

[0076] The recitation 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.

[0077] The expressions "connected", "coupled", and "in communication" 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 with each other. The term "abutting" refers to articles that are physically in direct contact with each other, although the articles need not necessarily be attached to each other.

[0078] 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 preferred or advantageous over other embodiments. Although various aspects of the embodiments are presented in the drawings, the drawings are not necessarily drawn to scale unless otherwise specified.

[0079] References throughout this specification to "an embodiment" or "this embodiment" mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the above phrases or variations thereof throughout the specification are not necessarily all referring to the same embodiment.

[0080] Similarly, it should be understood that in the description of the embodiments above, for the purpose of organizing the disclosure, various features may in some cases be grouped in a single embodiment, drawing, or description thereof. However, this method of disclosure should not be construed as reflecting an intention that this application or any application claiming priority to this application requires more features than are expressly recited in its claims. Rather, as the following claims show, inventive aspects may lie in combinations of fewer features than all features of any one of the embodiments disclosed above. Accordingly, the claims following this detailed description are expressly incorporated into this detailed description, and each claim stands on its own as a separate embodiment. The present disclosure is intended to be construed to include all variations of the independent claims and their dependent claims.

[0081] According to embodiments of the present invention, the system and method can be implemented by the use of one or more computing devices. Those skilled in the art will recognize that typical systems suitable for use with the embodiments of this application generally include a central processing unit (CPU), random access memory (RAM), storage media (such as hard disk drives, solid state drives, flash memory, cloud storage), an operating system (OS), one or more application softwares, display elements, one or more communication means, or one or more input / output devices / means. Examples of computing devices that can be used with the embodiments of the present invention include, but are not limited to, proprietary computing devices, personal computers, mobile computing devices, tablet PCs, mini-PCs, servers, or any combination thereof. Also, the term computing device can represent two or more computing devices communicatively linked to distribute and share one or more resources, such as clustered computing devices and server banks / farms. Those skilled in the art will understand that any number of computing devices can be used and that the embodiments of the present invention are intended for use with any computing device.

[0082] In various embodiments, communication means, data store(s), processor(s), or memory may interact with other components on the computing device to perform the provision and display of various functions associated with the systems and methods detailed herein. Those skilled in the art will recognize that there are numerous configurations that can be utilized in the embodiments of the present invention and that the embodiments of the present invention are intended for use with any suitable configuration.

[0083] According to an embodiment of the present invention, the communication means of the system may be any means for communicating data, for example, via one or more networks or to one or more peripheral devices attached to the system. Suitable communication means may include, but are not limited to, circuits and control systems for providing wireless connections, wired connections, cellular connections, data port connections, Bluetooth connections, or any combination thereof. Those skilled in the art will recognize that there are numerous communication means that can be utilized in embodiments of the present invention and that embodiments of the present invention are intended for use with any communication means.

[0084] Throughout this disclosure and others, block diagrams and flowcharts illustrate methods, apparatus (i.e., systems), and computer program products. Each element of the block diagrams and flowcharts, and each combination of the respective elements within the block diagrams and flowcharts, represents functions of the methods, apparatus, and computer program products. Any and all such functions (the "illustrated functions") can be implemented by computer program instructions, by a dedicated hardware-based computer system, by a combination of dedicated hardware and computer instructions, by a combination of general-purpose hardware and computer instructions, etc., and any and all of them can generally be referred to herein as "circuits," "modules," or "systems."

[0085] The above-described drawings and descriptions may describe the functional aspects of the disclosed system, but the specific configuration software for implementing these functional aspects cannot be inferred from these descriptions unless specifically specified or apparent from the context.

[0086] Each element within the flowchart diagram may represent a step or a group of steps of a computer-implemented method. Also, each step may include one or more sub-steps. For purposes of illustration, these steps (as well as any and all other steps identified and described above) are presented in order. It is understood that embodiments may include steps in a different order adapted to specific use cases of the technology disclosed herein. All such variations and modifications are intended to fall within the scope of the present disclosure. The illustration and description of steps in any particular order are not required in a particular use case and are not intended to exclude embodiments having steps in a different order unless specifically specified or apparent from the context.

[0087] Conventionally, a computer program is composed of a sequence of computing instructions or program instructions. As understood, a programmable device (i.e., a computing device) can receive such a computer program and, by processing its computing instructions, bring about further technical effects.

[0088] A programmable device may 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, etc., which can be appropriately utilized or configured for processing computer program instructions, executing computer logic, storing computer data, and the like. Throughout the present disclosure and others, a computer may include any and all suitable combinations of at least one general-purpose computer, special-purpose computer, programmable data processing device, processor, processor architecture, and the like.

[0089] It is understood that the computer may include a computer-readable storage medium, and this medium may be internal or external, removable, and replaceable, or fixed. Also, the computer may include a basic input / output system (BIOS), firmware, operating system, database, etc. that can include, interface with, or correspond to the software and hardware described herein.

[0090] Embodiments of the systems as described herein are not limited to use cases that include conventional computer programs or programmable devices that execute them. For example, embodiments of the present invention that are the subject of the claims may conceivably include optical computers, quantum computers, analog computers, and the like.

[0091] Regardless of the type of computer program or computer involved, the computer program can be loaded into a computer to generate a particular machine capable of performing any and all of the illustrated functions. This particular machine provides means for executing any and all of the illustrated functions.

[0092] Any combination of one or more computer-readable media may be used. The computer-readable media may be a computer-readable signal medium or a computer-readable storage medium. The computer-readable storage medium may be, for example, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing, but is not limited thereto. More specific examples of the computer-readable storage medium include 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 disk 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, the computer-readable storage medium may 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.

[0093] Computer program instructions may be stored in a computer-readable memory that can direct a computer or other programmable data processing device to function in a particular manner. The instructions stored in the computer-readable memory constitute a product including computer-readable instructions for performing any and all of the illustrated functions.

[0094] The computer-readable signal medium may include a propagated data signal in which computer-readable program code is embodied, for example, baseband or as part of a carrier wave. Such a propagated signal may be in any of a variety of forms including, but not limited to, electromagnetic, optical, or any suitable combination thereof. The computer-readable signal medium may 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.

[0095] Program code embodied on a computer-readable medium can be transmitted using any suitable medium including, but not limited to, wireless, wired, fiber optic cable, RF, or any suitable combination of the foregoing.

[0096] The elements shown in flowchart diagrams and block diagrams throughout the drawings imply logical boundaries between the elements. However, depending on the software or hardware engineering approach, the illustrated elements and their functionality can be implemented as part of a monolithic software structure, as stand-alone software modules, or as modules using external routines, code, services, etc., or any combination thereof. All such implementations are within the scope of the present disclosure.

[0097] Unless otherwise specified or apparent from the context, the verbs "execute" and "process" are used synonymously and denote performing, processing, interpreting, compiling, assembling, linking, loading, and any and all combinations thereof, etc. Thus, embodiments that execute or process computer program instructions, computer-executable code, etc. can act upon the instructions or code appropriately in any and all of the methods described above.

[0098] The functions and operations presented in this specification are not inherently related to any particular computer or other device. Various general-purpose systems may be used with the programs according to the teachings of this specification, or it may prove convenient to configure more specialized devices to perform the required method steps. The structures required for these various systems will be apparent to those skilled in the art, along with equivalent variations. Additionally, embodiments of the present invention are not described with reference to any particular programming language. It is recognized that various programming languages may be used to implement the teachings as described herein, and that references to specific languages are provided to disclose the practicability and optimal mode of embodiments of the present invention. Embodiments of the present invention are adaptable to a wide variety of computer network systems spanning numerous topologies. In this field, the configuration and management of large-scale networks involve storage devices and computers communicatively coupled to different computers and storage devices via a network such as the Internet, for example.

[0099] Numerous implementations have been described. However, it is understood that various modifications may be made. For example, if the steps of the disclosed technology are performed in a different order, or if the components of the disclosed system are combined differently, or if other components are supplemented to the components, advantageous results may be achieved. Accordingly, other implementations are considered to be within the scope of the following claims.

Claims

Claim 1. An apparatus comprising: a power source; a control device connected to the power source; a welding device selectively connected to the power source via a contactor of the control device; a switch connected between a time delay relay of the control device and the welding device; wherein: the time delay relay measures a predetermined period, which is initiated in response to a welding arc generated by the welding device when the welding device is tapped on a conductive surface by a user; the time delay relay is connected to a contactor that selectively connects the welding device to the power source; the switch maintains a closed position when the predetermined period has expired and the welding device continues to generate the welding arc; the switch switches from the closed position to an open position both when the predetermined period has expired and when the welding device stops generating the welding arc; and the control device transmits current from the power source to the welding device when the switch is in the closed position and interrupts the current from the power source to the welding device when the switch is in the open position. Claim 2. The apparatus according to claim 1, wherein the switch is a magnetic switch. Claim 3. The apparatus according to claim 1, wherein the switch maintains the closed position when the predetermined period has not elapsed or when the welding device generates the welding arc when the predetermined period expires and continuously generates the welding arc without interruption after the expiration of the predetermined period. Claim 4. The apparatus according to claim 1, wherein the switch switches from the closed position to the open position when the predetermined period has expired and the welding device stops generating the welding arc, or when the welding device continues to generate the welding arc after the expiration of the predetermined period and then stops generating the welding arc for the first time after the expiration of the predetermined period. Claim 5. The apparatus according to claim 1, wherein the switch switches from the open position to the closed position when the user taps the welding device on the conductive surface. Claim 6. The apparatus according to claim 5, wherein the time delay relay includes a timer that starts the predetermined period when the user taps the welding device on the conductive surface.

7. The apparatus according to claim 1, wherein the contactor has a coil that is selectively energized by the switch.

8. When the switch is in the closed position, the switch transmits current to the coil, thereby activating the contactor to electrically connect the power source to the welding device, and When the switch is in the open position, the coil remains de-energized and the contactor electrically disconnects the power source from the welding device. The apparatus according to claim 7.

9. A first electrical connector that electrically connects the power source to the power input of the control device, A second electrical connector that is disposed within the control device and connects the power input to a contactor that is electrically connected to the power output of the control device, A third electrical connector that electrically connects the power output to the welding device, A fourth electrical connector that electrically connects the welding device to the time delay relay, The apparatus according to claim 7, further comprising.

10. The apparatus according to claim 9, wherein the switch is disposed on the fourth electrical connector.

11. 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. The apparatus according to claim 9.

12. The apparatus further comprises a network server that communicates with a controller of the control device, and The controller transfers data to the network server. The apparatus according to claim 1.

13. A method comprising: Providing a power source and a welding device; Electrically disposing a control device between the power source and the welding device, wherein the welding device is selectively connected to the power source via a contactor of the control device; Disposing a switch between a time delay relay of the control device and the welding device; Measuring a predetermined period with a time delay relay of the control device, wherein the predetermined period is started in response to a welding arc generated by the welding device when the welding device is tapped on a conductive surface by a user. connecting the time delay relay to a contactor that selectively connects the welding device to the power source; maintaining the switch in the closed position when the predetermined period has elapsed and the welding device continues to generate the welding arc; switching the switch from the closed position to the open position both when the predetermined period has elapsed and when the welding device stops generating the welding arc; transmitting current from the power source to the welding device via the control device when the switch is in the closed position; interrupting the current from the power source to the welding device via the control device when the switch is in the open position; A method comprising the steps of:

14. when the predetermined period has not elapsed, or when the welding device is generating the welding arc when the predetermined period elapses and continues to generate the welding arc without interruption after the expiration of the predetermined period, The method according to claim 13, further comprising maintaining the closed position.

15. when the predetermined period has elapsed and the welding device has stopped generating the welding arc, or when the welding device continues to generate the welding arc after the expiration of the predetermined period and then stops generating the welding arc for the first time after the expiration of the predetermined period, The method according to claim 13, further comprising switching the switch from the closed position to the open position.

16. Switching the switch from the open position to the closed position when the user taps the welding device on the conductive surface, and starting the timing of the predetermined period when the user taps the welding device on the conductive surface. The method according to claim 13, further comprising the steps of:

17. transmitting current from the switch to the contactor of the control device to activate the contactor to electrically connect the power source to the welding device when the switch is in the closed position; maintaining the coil of the contactor in a de-energized state to electrically disconnect the power source from the welding device when the switch is in the open position; The method according to claim 13, further comprising the steps of:

18. An apparatus comprising: a power source, A control device having a power input connected to the power supply via a first electrical connector, A welding device selectively connected to the power supply via a second electrical connector of the control device, wherein the second electrical connector connects the power input to a contactor of the control device that is electrically connected to the power output of the control device, A magnetic switch connected between a time delay relay of the control device and the welding device, wherein the time delay relay measures a predetermined period, and the predetermined period is started in response to a welding arc generated by the welding device when the welding device is tapped on a conductive surface by a user, A third electrical connector electrically connecting the power output to the welding device, A fourth electrical connector electrically connecting the welding device to a time delay relay of the control device, An apparatus comprising, The time delay relay is electrically connected to the contactor, The magnetic switch maintains a closed position when the predetermined period has expired and the welding device continues to generate a welding arc, The magnetic switch switches from the closed position to the open position both when the predetermined period has expired and when the welding device stops generating the welding arc, and The control device transmits current from the power supply to the welding device when the magnetic switch is in the closed position and interrupts the current from the power supply to the welding device when the magnetic switch is in the open position.

19. The magnetic switch is disposed on the fourth electrical connector, The control device is electrically connected between the power supply and the welding device, and The time delay relay is electrically connected between the magnetic switch and the contactor, The apparatus according to claim 18.

20. The welding device that generates the welding arc creates a magnetic field that closes the magnetic switch, and When the welding device stops generating the welding arc, the magnetic field stops, and when the predetermined period has expired, the magnetic switch switches from the closed position to the open position, The apparatus according to claim 18.

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