Weld Cable Communication for Remote Arc Voltage Compensation

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Solution Overview

Problem

Welding applications often require long welding power cables, leading to significant voltage drops between the power source and the workpiece, which can result in inaccurate weld voltages. This necessitates frequent adjustments and can be hazardous due to the need for workers to traverse long distances to manage cables and settings.

Innovation Solution

The implementation of a welding power supply system that utilizes weld cable communications to enable voltage sensing and feedback from a remote wire feeder. This system adjusts the arc voltage to compensate for voltage drops over the weld cable, ensuring accurate weld voltages without the need for additional communication cables or unreliable wireless equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If long welding power cables are used to extend the welding location distance from the power source, then the welding location flexibility is improved, but the voltage drop between the power source and the workpiece increases

Engineering Contradiction:

Improvewelding location distanceVSAvoidvoltage drop

Core Design Contradiction:

Length of moving objectVSLoss of energy

Solution Approach 1:

The system measures the actual weld voltage at the wire feeder location and feeds this information back to the power source controller. The controller then adjusts the output voltage to compensate for the voltage drop in the weld cable, ensuring accurate weld voltage delivery despite long cable lengths.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces the need for additional communication cables or wireless equipment by using the existing weld circuit to transmit voltage measurements and control signals. This substitutes a complex mechanical communication system with a simpler electrical signal transmission over the weld circuit.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If the power terminals and controls are positioned on or proximate to the welding power source, then the control system simplicity is improved, but the operational convenience deteriorates due to frequent worker movement over long distances

Engineering Contradiction:

Improvecontrol system structureVSAvoidworker accessibility

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The wire feeder is equipped with voltage sensing and communication capabilities, enabling it to autonomously measure the weld voltage and transmit this information back to the power source. This eliminates the need for workers to manually monitor or adjust settings at the power source location.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The weld circuit itself serves as an intermediary medium, carrying both the welding current and the communication signals between the power source and the wire feeder. This eliminates the need for separate control cables and reduces the need for worker intervention.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If additional communication cables or wireless communication equipment are used to enable remote voltage monitoring and adjustment, then the voltage control accuracy is improved, but the device complexity and reliability increase

Engineering Contradiction:

Improveweld voltage accuracyVSAvoidcommunication system components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The weld circuit is made multi-functional by using it for both welding current transmission and communication signal transmission. This eliminates the need for separate communication cables or wireless equipment, reducing system complexity while maintaining voltage measurement and control accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the power transmission function and the communication function into a single weld circuit. The voltage measurements and control signals are superimposed on the welding current path, eliminating the need for additional communication infrastructure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12240063B2Welding power supplies, wire feeders, and systems to compensate a weld voltage via communications over a weld circuit

Publication Date: 2025.03.04 ILLINOIS TOOL WORKS INC

AI summary

Methods and apparatus to communicate via a weld cable are disclosed. An example weld circuit communications device includes a receiver circuit, a processor, and a local communications adapter. The receiver circuit to receive a communication via a weld circuit while current is flowing through the weld circuit or after the current has stopped flowing through the weld circuit, the communication including weld voltage feedback information measured at a device remote from a power supply and remote from the weld circuit communications device while the current is flowing through the weld circuit. The processor generates power supply control information based on the weld voltage feedback information. The local communications adapter transmits the power supply control information to control welding-type power output by a power converter to regulate a weld voltage to a weld voltage setpoint.