Weld Cable Remote Control via Signal Modulation
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Solution Overview
Problem
Existing remote control systems for welding machines are prone to damage due to fragility, suffer from radio frequency interference, and have limitations in data transmission capacity, especially in industrial environments where they are often used.
Innovation Solution
A system that uses a weld cable as a communication link to transmit control information between a power source and a wire feeder, employing serialized and encoded communication methods, and leveraging the open circuit voltage (OCV) as a backbone for control command transmission, eliminating the need for a separate control cable and enabling battery-less operation of the wire feeder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate control cable is used to transmit control signals between power source and wire feeder, then control functionality is achieved, but the system becomes more complex and the control cable becomes fragile and prone to damage
Solution Approach 1:
The patent combines the control signal transmission and power delivery functions into a single weld cable. The control signals are transmitted by modulating the weld cable itself, eliminating the need for a separate control cable. This merging of functions reduces system complexity and removes the fragile control cable that was prone to damage in industrial environments.
2Ease of operation
If a separate control cable is used for remote control, then control signals can be transmitted, but the cable becomes vulnerable to damage from crushing or snagging in mobile industrial environments
Solution Approach 1:
The control signals are transmitted through the weld cable that is already present and robust in the system, rather than using a separate control cable. The weld cable is designed to handle high currents and is therefore much more durable and resistant to crushing or snagging in mobile industrial environments.
Solution Approach 2:
The weld cable serves multiple functions: it delivers welding power and simultaneously transmits control signals. By making the weld cable multi-functional, the system eliminates the need for an additional dedicated control cable, thereby improving reliability without sacrificing remote control capability.
3Ease of operation
If radio frequency transmission is used for remote control, then wireless operation is achieved, but radio frequency interference from electric arc welding negatively affects communication
Solution Approach 1:
Instead of using radio frequency transmission that is susceptible to interference from electric arc welding, the patent uses the weld cable as an intermediary medium to transmit control signals. The control signals are superimposed on the weld cable, which acts as a shielded transmission medium immune to the electromagnetic interference generated by the welding arc.
4Ease of operation
If pulse width modulation is used to transmit control data across the weld cable, then remote control is achieved, but the data transmission capacity and variability are limited
Solution Approach 1:
The patent employs frequency and voltage decoding schemes that allow for greater variability and capacity in control signal transmission compared to pulse width modulation. By utilizing multiple parameters (frequency and voltage levels) for encoding control information, the system can transmit more diverse and detailed operational parameters between the power source and wire feeder.
Data Source
AI summary
The present invention is directed to a remote control that uses a welding circuit to transfer control information to a welding power source. The information to be communicated to the power source includes welding power source output command information (amperage/voltage control), welding circuit on/off information (power source output contactor control), and power source mode control (constant voltage/constant current). The control information may be transmitted in a serial communication and/or encoded using frequency and or voltage coding. The control information may be transmitted during dedicated transmission intervals or as an offset to an open circuit voltage between the power source and wire feeder.