Master Node Wireless Control for Welding Power Optimization
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Solution Overview
Problem
Welding equipment in remote locations faces challenges with long cable extensions, noise interference, and security concerns in harsh environments, limiting effective wireless communication for control and data exchange.
Innovation Solution
A system comprising a master node device with communication and control circuitry that facilitates long-range communication with welding power supplies and short-range communication with welding equipment, managing power consumption by synchronizing sleep modes, and implementing secure association protocols to form a local wireless network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wireless communication is used in harsh environments, then cable extension problems are eliminated, but noise interference and security concerns worsen
Solution Approach 1:
The patent introduces a wireless communication system as an intermediary between the welding equipment and control devices, replacing physical cable connections. This mediator enables data transmission without direct physical contact, eliminating cable extension issues while implementing protocols to handle noise interference and security concerns through signal processing and encryption mechanisms.
Solution Approach 2:
The patent replaces the mechanical cable-based communication system with an electromagnetic wireless communication system. This substitution eliminates the physical constraints of cable extensions and allows flexible positioning of welding equipment while using radio frequency signals to transmit control data and sensor information without physical connections.
2Ease of operation
If wireless communication is used in harsh environments, then cable extension problems are eliminated, but reliability of communication worsens
Solution Approach 1:
The patent implements feedback mechanisms where receiving devices confirm successful data reception and transmitting devices adjust their transmission parameters based on signal quality feedback. This closed-loop communication system detects and corrects errors, ensuring reliable data transmission despite the harsh environmental conditions and eliminating the need for physical cable connections.
3Use of energy by moving object
If sleep mode synchronization is implemented, then power consumption is reduced, but communication responsiveness worsens
Solution Approach 1:
The patent implements periodic wake-up cycles where devices alternate between sleep mode and active communication mode. During sleep mode, devices consume minimal power, but they periodically wake up to check for incoming messages or transmit scheduled data. This periodic operation significantly reduces average power consumption while maintaining acceptable communication responsiveness for welding applications.
Solution Approach 2:
The patent employs dynamic power management where devices adjust their sleep wake-up intervals and transmission power levels based on operational conditions. When welding activity is detected or expected, devices wake up more frequently to ensure responsive communication. During idle periods, they extend sleep duration to minimize power consumption, creating a dynamic balance between energy savings and communication responsiveness.
Data Source
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AI summary
In certain embodiments, a system includes a master node device. The master node device includes communication circuitry configured to facilitate communication with a welding power supply unit via a long-range communication link, and to facilitate wireless communication with one or more welding-related devices via a short-range wireless communication network. The master node device also includes control circuitry configured to manage power consumption of on-board batteries of the master node device and the one or more welding-related devices.