Remotely Controlled Welding Machine Using Circuit Signal Integration
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Solution Overview
Problem
Existing remote control systems for welding machines are prone to damage due to fragility, require separate contactor assemblies, and suffer from radio frequency interference and shielding issues, limiting their effectiveness in industrial settings.
Innovation Solution
A remotely controlled welding system that uses the welding circuit to transfer command signals between a wire feeder and power source, eliminating the need for a separate control cable and contactor assembly, and utilizing a transmitter and receiver to control the power source only when the welding process is activated, thus preventing open circuit voltage across the weld cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate control cable and contactor assembly are used for remote control, then reliable control signals can be transmitted, but the system becomes more complex and fragile
Solution Approach 1:
The patent combines the control signal transmission function with the existing weld cables by using the weld cables to carry both welding current and control signals. This eliminates the need for a separate control cable and contactor assembly, reducing system complexity while maintaining reliable control signal transmission through the integrated cable system
Solution Approach 2:
The weld cables are designed to serve multiple functions: transmitting welding current and simultaneously carrying control signals for power source operation. This multi-functionality eliminates the need for dedicated control cables and contactor assemblies, simplifying the overall system while maintaining reliable control
2Reliability
If a separate control cable is used, then control functions are reliable, but the cable becomes fragile and susceptible to damage
Solution Approach 1:
The control signals are integrated into the weld cable system that is already designed to handle high currents and harsh industrial environments. By combining control signal transmission with the robust weld cable infrastructure, the system maintains reliable control functions while eliminating the vulnerability of separate fragile control cables
Solution Approach 2:
The weld cable system serves itself by carrying both welding current and control signals through the same infrastructure. This self-service approach eliminates the need for additional separate control cables that would be susceptible to damage, as the existing weld cables are already designed for rugged industrial use
3Ease of operation
If voltage is created continuously across weld cables, then power source is ready for welding, but safety risks increase from unwanted arcs
Solution Approach 1:
The power source creates voltage across the weld cables only periodically when control signals indicate welding is required, rather than continuously. This periodic activation maintains power source readiness when needed while minimizing the time voltage is present, thereby reducing safety risks from unwanted arcs in case of cable damage
Solution Approach 2:
The control signals are transmitted through the weld cables before voltage is created across them. This preliminary action allows the system to verify cable integrity and readiness through control signal transmission, then only creates voltage when and when the welding process is actually initiated, reducing the window of vulnerability to unwanted arcs
Data Source
AI summary
The present invention is directed to a remotely controlled welding machine. A remote control uses the welding circuit to transfer 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). A transmitter transmits the desired welding operational parameters to a receiver disposed in the power source. The transmitter is constructed to use only a small amount of power which, preferably, is supplied by one or two low voltage replaceable and/or rechargeable batteries. Additionally, an open circuit voltage is not created between the power source and an electrode holder when an arc is not present.