Brand-agnostic welding parameter analyzer and monitoring system

Abstract

The present invention relates to a brand-agnostic welding parameter monitoring system, termed the Analyser Pro, designed to address the limitations of existing solutions by offering universal compatibility and advanced capabilities. The system comprises a central processing module, sensors for measuring critical welding parameters (such as voltage, current, and gas flow), and connectivity modules for real-time monitoring and data transfer. The Analyser Pro enables comprehensive data logging, real-time feedback,and automated report generation, ensuring improved weld quality and process optimization. Modular and scalable, the system includes advanced safety features and is suitable for diverse industrial applications, enhancing operational efficiency and compliance with quality standards.

Description

[0001] BRAND-AGNOSTIC WELDING PARAMETER ANALYZER AND MONITORING SYSTEM

[0002] FIELD OF INVENTION

[0003]

[0001] The present invention relates to the field of welding parameter monitoring systems, particularly to a brand-agnostic system that monitors, analyzes, and logs critical parameters such as voltage, current, and gas flow during welding processes. The present invention aims to enhance efficiency, flexibility, and operational control in industrial welding operations.

[0004] BACKGROUND OF INVENTION

[0005]

[0002] Welding processes are critical in manufacturing and industrial applications, where precision and quality play a pivotal role. Achieving consistent weld quality requires accurate monitoring and control of essential parameters such as voltage, current, and gas flow. However, existing monitoring solutions often suffer from limitations, including brand dependency, restricted parameter tracking, and lack of automated data management. These constraints result in inefficiencies, inconsistencies, and increased operational costs.

[0006] PRIOR ART

[0007]

[0003] A prior art having application no. US20120145688A1 discloses A weld monitoring and recording system and method monitors an ongoing welding operation and compares the welding current, the welding voltage, pre- heat / inter-pass temperature or other parameters from a previously qualified weld that are stored within a programmable device or computer. If the monitored parameters vary from the qualified parameters, then the weld is automatically interrupted until the operating parameters once again match the stored qualified parameters. A recorder can record different values related to the ongoing welding operation in order to provide documentation about the weld that can be viewed, printed, or downloaded.

[0004] Another prior art having application no. US20140042136A1 discloses a system and method for collecting one or more welding parameters in real time during creation of one or more welds using a welding sequence. The one or more welding parameters can be associated with a particular welding sequence. Moreover, based on the one or more welding parameters collected, a modeled welding parameter can be generated to increase quality, efficiency, and the like. A collection component collects real time welding parameter data from which a quality manager component creates a modeled welding parameter. The modeled welding parameter can be employed for the welding sequence to monitor or track the welding parameter during a subsequent weld.

[0008]

[0005] Another prior art having application no. US6236017B1 discloses apparatus for determining a quality of a weld produced by a welding device according to the present invention includes a sensor operatively associated with the welding device. The sensor is responsive to at least one welding process parameter during a welding process and produces a welding process parameter signal that relates to the at least one welding process parameter. A computer connected to the sensor is responsive to the welding process parameter signal produced by the sensor. A user interface operatively associated with the computer allows a user to select a desired welding process. The computer processes the welding process parameter signal produced by the sensor in accordance with one of a constant voltage algorithm, a short duration weld algorithm or a pulsed current analysis module depending on the desired welding process selected by the user. The computer produces output data indicative of the quality of the weld.

[0009]

[0006] However, none of the aforementioned prior art solutions addresses the above issues by introducing a universal, hardware -based solution. The present system offers compatibility with various welding machine brands and advanced features for real-time monitoring, data logging, and quality assurance. The present system ensures enhanced productivity, operational flexibility, and reduced downtime.

[0010]

[0007] Thus, there arises a need for an adaptive experience planning, booking and management platform based on a system and a method to overcome the existinglimitations of the state of the art and offer the aforementioned features in a comprehensive manner on a single platform.

[0011] OBJECTIVE OF INVENTION

[0012]

[0008] It is a general or primary object of the present invention is to provide for a universal, brand- agnostic welding parameter monitoring system that provides seamless integration with a wide range of welding machines, ensuring compatibility and flexibility for various industrial applications.

[0013]

[0009] Another object of the present invention is to enhance welding process efficiency and quality by enabling real-time monitoring, data analysis, and automated reporting of critical welding parameters, ensuring consistent and optimized welds.

[0014]

[0010] Another object of the present invention is to provide for a modular and scalable system that can be customized and expanded with additional sensors or modules to meet the specific needs of various industrial applications.

[0015] [Oil] Another object of the present invention is to integrate advanced connectivity features, such as Wi-Fi, Bluetooth, and Ethernet, allowing for remote monitoring, data transfer, and cloud-based integration, enabling centralized management and real-time feedback.

[0016]

[0012] Another object of the present invention is to provide for an automated report generation capability, allowing for the generation of comprehensive reports on welding parameters, performance, deviations, and quality control for compliance with industry standards.

[0017]

[0013] Another object of the present invention is to support predictive maintenance by analyzing welding parameter trends, identifying potential issues before they lead to equipment failure, and enabling proactive maintenance to reduce downtime and to ensure safety in welding operations by detecting anomalies such as gas leaks or voltage surges, alerting operators immediately to prevent accidents and maintain a safe working environment.

[0014] Another object of the present invention is to enhance the overall efficiency of industrial welding operations by providing comprehensive, real-time data for monitoring and ensuring consistent quality across all welding processes.

[0018]

[0015] These and other objects of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.

[0019] SUMMARY OF INVENTION

[0020]

[0016] The present invention provides for Analyser Pro, a sophisticated hardware system designed to monitor, analyze, and log welding parameters independently of the welding machine’s brand. It comprises sensors for voltage, current, and gas flow monitoring, a central processing module, and advanced connectivity options for remote access and reporting. With features like automated alerts and comprehensive report generation, the Analyser Pro empowers users to optimize their welding processes effectively. Key features include a brand-agnostic design compatible with all welding machine brands, real-time monitoring that provides instant feedback, comprehensive data logging for analysis and quality control, automated reporting for performance insights, modular and scalable design, and connectivity options like Wi-Fi, Bluetooth, and Ethernet for remote operations.

[0021] DESCRIPTION OF EMBODIMENTS

[0022]

[0017] For promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.

[0023]

[0018] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

[0019] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other sub-systems, elements, structures, components, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0024]

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0025]

[0021] Embodiments of the present invention will be described below in detail with reference to the accompanying figure la, Figure lb, and figure 2.

[0026]

[0022] The present invention relates to an

[0027]

[0023] Embodiment 1: System Configuration

[0028]

[0024] In one embodiment, the Analyser Pro includes a central processing module, which serves as the brain of the system, equipped with a high-speed processor and memory units. This module processes real-time data from multiple sensors and facilitates data logging and report generation. The sensors comprise:

[0029] (a) Voltage Sensor: Measures the electrical potential difference across the welding arc with precision.

[0030] (b) Current Sensor: Tracks the current flow during welding to ensure consistency and quality.

[0031] (c) Gas Flow Sensor: Monitors shielding gas flow rates to maintain optimal welding conditions.(d) Optional Sensors: These may include wire feed speed sensors, temperature monitors for the heat-affected zone, and pressure sensors for advanced applications.

[0032]

[0025] The system’s modular design allows additional sensors to be incorporated based on specific industrial requirements. These sensors are strategically placed at the welding machine’s output terminals to capture critical data during operations.

[0033]

[0026] Embodiment 2: Real-Time Monitoring and Connectivity

[0034]

[0027] In another embodiment, the Analyser Pro features advanced connectivity modules such as Wi-Fi, Bluetooth, and Ethernet, which enable remote monitoring and seamless data transfer to cloud-based systems. This connectivity supports real-time synchronization of data, allowing operators to track welding parameters from remote locations. A user-friendly display interface provides real-time feedback and alerts for deviations, enabling operators to take immediate corrective actions. The system also integrates automated reporting capabilities, generating detailed performance insights and compliance documentation.

[0035]

[0028] In some aspects, the Analyser Pro includes software that facilitates the sharing of welding data across companies and within supply chains, similar to file sharing systems like Google Drive. This feature is particularly useful for large corporations with complex supply chains, such as Caterpillar, which may work with multiple tiers of suppliers. Through this system, a company (e.g., Caterpillar) can set Welding Procedure Specifications (WPS) for a specific product, project, or welding operation. These WPS parameters can then be shared across various vendors and subcontractors in the production hierarchy, ensuring compliance at every level. Each participant in the supply chain, from Tier 1 to Tier N vendors, must follow the WPS guidelines for consistency in the welding process. Additionally, with appropriate permissions, real-time welding data can be accessed by different parties within the production hierarchy, enabling live monitoring and feedback.

[0036]

[0029] Embodiment 3: Integration with Automation

[0030] An alternative embodiment involves the integration of the Analyser Pro with robotic welding systems. In this configuration, the device provides real-time parameter feedback to ensure consistent weld quality in automated operations. The system’s data logging module supports predictive maintenance by identifying trends and potential issues before they affect production.

[0037]

[0031] Method of Operation

[0038]

[0032] The Analyser Pro’s method of operation ensures precision, efficiency, and adaptability to diverse industrial needs. The steps involved are:

[0039] (a) Setup and Connection: The system is connected to the output terminals of a welding machine. Sensors are attached to measure parameters such as voltage, current, gas flow, and other optional variables.

[0040] (b) Data Acquisition: During the welding process, the sensors collect realtime data, which is transmitted to the central processing module. The module ensures that all measurements are accurate and consistent. (c) Data Analysis: The central processing module analyses the collected data against predefined thresholds set by the operator. If any deviation is detected, the system triggers alerts.

[0041] (d) Feedback and Display: The processed data is displayed in real-time on the interface, providing operators with immediate feedback. Alerts for anomalies are clearly indicated through visual or audible signals. In some aspects, in addition to providing real-time feedback on the welding parameters, the Analyser Pro also includes multi-channel alert options when a welder deviates from the configured parameters. Feedback may be delivered through various devices such as a screen, a tower lamp, an audible buzzer, a wristwatch, or even a helmet with an integrated display. This allows operators and welders to receive immediate alerts in a manner most suited to their environment, ensuring that deviations are noticed promptly and corrective actions can be taken.

[0042] (e) Data Logging: All measured parameters and analysis results are logged into the system’s memory for post-process evaluation. This data forms the basis for detailed reporting and quality control.(f) Report Generation: The system automatically generates reports summarizing the welding process, highlighting any deviations and areas for improvement. Reports can be exported or integrated with external systems for further analysis.

[0043] (g) Cloud Integration (Optional): For advanced setups, the system uploads the collected data to a cloud-based platform, enabling remote access, predictive maintenance, and centralized management of multiple welding operations.

[0044] (h) The Analyser Pro includes a variety of feedback options when welders work outside of the pre-configured parameters. Alerts can be received via different devices, such as a screen display, tower lamps, buzzers, or wearable devices like wristwatches and helmets with integrated displays. This ensures that the welder receives instant, clear feedback regardless of their position or the environment in which they are working.

[0045]

[0033] Examples

[0046]

[0034] Example 1: During a MIG welding operation, the Analyser Pro measures a voltage of 20 Volts, current of 150 Ampere, and a gas flow rate of 15 L / min. These parameters fall within the optimal range 18-24 Volt, 140-160 Ampere, and 12-20 L / min, and the system logs the data while providing real-time feedback to the operator. In some aspects, the system records the value even if its outside the optimal range as it is required for inspection and improvement like training the welder, identifying mistakes etc.

[0047]

[0035] Example 2: In a TIG welding setup, the system detects a current flow deviation, dropping below 50 Ampere. The anomaly triggers an immediate alert, prompting the operator to adjust the machine’s settings, thereby maintaining weld quality. In some aspects, the system has setting to just give alert or even to stop welding process until approved again by a supervisor, further, the settings may be configurable.

[0048]

[0036] Example 3: In a production environment utilizing multiple welding machines, the Analyser Pro monitors each machine individually. At the end of the shift, itgenerates a detailed report summarizing the performance of each machine and operator, highlighting areas needing improvement.

[0049]

[0037] Customization and Scalability

[0050]

[0038] The Analyser Pro’s modular and scalable architecture allows it to be tailored for various industrial applications. Additional functionalities, such as weld seam quality assessment, heat-affected zone monitoring, and metal composition analysis, can be incorporated into the system. These enhancements make the Analyser Pro a versatile tool suitable for small workshops and large industrial setups alike. By integrating advanced safety mechanisms, real-time feedback, and remote monitoring, the Analyser Pro represents a significant leap forward in welding technology.

[0051] ADVANTAGES

[0052]

[0039] The Analyser Pro offers numerous advantages that address the critical needs of welding operations. These include:

[0053] (a) Brand-Agnostic Design: The system is compatible with all welding machine brands, providing flexibility to users with diverse equipment. (b) Comprehensive Parameter Monitoring: It measures voltage, current, gas flow, and optional parameters like wire feed speed and temperature, ensuring a holistic view of the welding process.

[0054] (c) Real-Time Feedback: Operators receive immediate alerts for parameter deviations, enabling them to make on-the-spot corrections and maintain quality.

[0055] (d) Data Logging and Automated Reporting: The system records all welding data and generates detailed reports, ensuring compliance with industry standards and aiding in process optimization.

[0056] (e) Remote Monitoring and Cloud Integration: Advanced connectivity options, including Wi-Fi, Bluetooth, and Ethernet, allow remote monitoring and centralized management through cloud-based platforms.(f) Scalability and Customization: Modular architecture allows the addition of sensors and functionalities tailored to specific industrial requirements.

[0057] (g) Enhanced Safety Features: Anomalies such as gas leaks or voltage surges are detected and flagged immediately, ensuring workplace safety. (h) Cost-Efficiency: By reducing the need for brand- specific equipment and automating quality assurance, the system lowers operational costs and increases productivity.

[0058] (i) Integration with Automation: The system’s ability to interface with robotic welding setups ensures consistency and high precision in automated operations.

[0059] (j) Predictive Maintenance: Through trend analysis and cloud-based data storage, the system supports proactive maintenance, reducing downtime and extending equipment life.

[0060]

[0040] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

[0061]

[0041] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, suchadaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

[0062]

[0042] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

Claims

We claim:

1. A welding parameter monitoring system Analyser Pro, the system comprises:(a) a central processing module;(b) a plurality of sensors connected to the central processing module for measuring welding parameters including voltage, current, and gas flow;(c) connectivity modules for enabling communication with remote devices, the modules including Wi-Fi, Bluetooth, and Ethernet; (d) a display interface configured to provide real-time feedback and alerts on welding parameters.

2. The system as claimed in claim 1, wherein the central processing module is configured to analyze the measured welding parameters against predefined thresholds, and trigger alerts in case of deviations.

3. The system as claimed in claim 1, wherein the system is compatible with welding machines of multiple brands, thereby providing a brand-agnostic solution for welding parameter monitoring.

4. The system as claimed in claim 1, further comprising a data logging module that stores the measured welding parameters for post-process evaluation, analysis, and reporting.

5. The system as claimed in claim 1, wherein the system is configured to generate automated reports summarizing the welding process, deviations, and areas for improvement.

6. The system as claimed in claim 1, wherein the sensors include a voltage sensor, a current sensor, and a gas flow sensor, and further optionally include wire feed speed sensors, temperature sensors, and pressure sensors.

7. The system as claimed in claim 1, wherein the connectivity modules support cloud-based data integration, enabling remote access and centralized management of multiple welding machines.

8. A method for monitoring welding parameters using the system as claimed in claim 1, the method comprising the steps of:(a) Connecting the system to a welding machine and configuring the sensors to monitor voltage, current, and gas flow;(b) Collecting real-time welding data from the sensors;(c) Analyzing the collected data for deviations from predefined thresholds;(d) Displaying real-time feedback and alerting operators of any deviations;(e) Logging the data for further analysis and report generation.

9. The method as claimed in claim 8, comprising the step of generating a report summarizing the performance of the welding operation, including parameter deviations, optimization suggestions, and compliance with quality standards.

10. The system as claimed in claim 1, wherein the system's modular design allows additional sensors or modules to be integrated for specialized monitoring and reporting needs, enabling the system to adapt to diverse industrial applications.