Welding Torch Type Recognition Over Two-Wire Power and Signal Lines
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Solution Overview
Problem
Conventional welding torches require additional wires and internal wiring modifications to achieve digital control, leading to loss of compatibility with non-customized welding machines.
Innovation Solution
Utilize two existing wires for both power supply and signal transmission, incorporating a welding torch control circuit with slots for analog and digital plug-in modules, and a voltage stabilization mechanism to enable adaptive function adjustments based on torch type recognition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If additional wires and internal wiring modifications are added to achieve digital control function, then digital control capability is improved, but compatibility with traditional welding machines deteriorates
Solution Approach 1:
The existing two-wire connection is designed to perform multiple functions simultaneously: power supply and digital signal transmission. The control circuit detects signal characteristics to distinguish between different wire configurations (two wires vs. three wires), enabling the system to adapt its control mode accordingly. This multi-functional design eliminates the need for separate dedicated digital control wires while maintaining compatibility with both traditional and digital welding machines.
Solution Approach 2:
The patent merges power supply function and digital control signal transmission function into the same two-wire connection. By combining these functions, the system achieves digital control capability without adding separate communication wires, thereby maintaining compatibility with traditional welding machine connections while enabling advanced control features.
2Adaptability or versatility
If two wires are used for both power supply and signal transmission, then compatibility is maintained, but signal transmission reliability may deteriorate due to voltage fluctuations
Solution Approach 1:
The patent introduces a capacitor as an intermediary element in the circuit to filter and stabilize voltage fluctuations on the two-wire connection. This capacitor acts as a mediator between the power supply function and signal transmission function, isolating digital control signals from voltage variations while allowing the same two wires to carry both power and control information reliably.
Solution Approach 2:
The control circuit continuously monitors signal characteristics and wire connection status, using feedback to dynamically adjust its operation mode. By detecting whether two or three wires are connected and analyzing signal properties, the system adapts its control strategy in real-time, ensuring reliable operation regardless of the wire configuration or voltage conditions.
Data Source
AI summary
A welding machine, a welding torch, a welding system, and a welding torch control method are provided. In the welding system, an electrical signal connection is established between the welding machine and the welding torch through wires, the welding machine utilizes the electrical signal connection to supply power to the welding torch, and recognizes the type of the welding torch according to an electrical signal received from the welding torch to obtain a welding torch type recognition result, and perform an adaptive adjustment on the specific function of the welding torch according to the welding torch type recognition result. The welding torch may have three welding torch control functions of common traditional mode control, analog control and digital control without the need of arranging extra wires in the welding machine and the welding torch or improving the existing wiring design of the traditional welding torch.