Welding Pendant Control Over a Shared Power and Data Cable
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Solution Overview
Problem
Existing welding technologies face challenges in remotely controlling welding power supply settings, leading to inefficiencies and increased costs due to the need for frequent movement between welding locations and power supplies, and limitations in wireless communication in harsh environments.
Innovation Solution
A welding pendant system that combines welding power and data transmission over a single welding power cable, allowing for remote control of welding power supply settings through a control panel, including current monitoring, enabling operators to adjust settings without returning to the power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding power and data are transmitted separately, then signal reliability is improved, but device complexity and cabling requirements increase
Solution Approach 1:
The patent combines power transmission and data communication into a single cable system. The welding power cable carries both electrical power and modulated data signals, eliminating the need for separate communication cables. This merging reduces system complexity while maintaining reliable communication through power line modulation techniques that are resilient to electromagnetic interference in welding environments.
Solution Approach 2:
The welding power cable is designed to perform multiple functions simultaneously: it serves as both a power delivery conduit and a data communication medium. By modulating data signals onto the power cable, the system achieves universal usage of existing infrastructure, eliminating the need for additional dedicated communication wiring while maintaining operational reliability.
2Measurement precision
If operators return to power supply to adjust settings, then control precision is improved, but productivity and time efficiency deteriorate
Solution Approach 1:
The patent introduces a remote control pendant as an intermediary device that allows operators to adjust welding parameters from a distance. The pendant communicates with the power supply through the existing power cable, enabling precise control of welding settings without requiring physical movement to the power supply location, thus maintaining control precision while improving productivity.
Solution Approach 2:
The system replaces the mechanical approach of physically moving to the power supply with an electrical/electronic communication system. Data signals are transmitted through the power cable to remotely adjust settings, substituting mechanical movement with electronic control to maintain precision while enhancing efficiency.
3Ease of operation
If wireless communication is used for remote control, then ease of operation is improved, but reliability deteriorates in harsh environments
Solution Approach 1:
The power cable acts as an intermediary medium for data transmission, leveraging the existing robust power delivery infrastructure. This approach provides ease of operation through remote control while ensuring reliability by using the physically protected power cable rather than vulnerable wireless signals in harsh welding environments.
4Reliability
If control cable is used for remote control, then reliability is improved, but weight and cost increase
Solution Approach 1:
The patent merges control signal transmission with power delivery in a single cable. By modulating data onto the existing power cable, the system achieves reliable control communication without adding the weight of separate control cabling, as the power cable infrastructure is already in place and carries both functions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances operational efficiency by allowing remote adjustment of welding parameters, reducing the need for frequent site changes and improving communication reliability, thereby minimizing costs and signal loss issues.
Implementation Method 1
The welding power is combined with the data such that the data is provided over the welding power cable
Implementation Method 2
The welding pendant includes a current sensor configured to monitor welding current of the welding power flowing between the welding power input and the welding power output
Data Source
AI summary
A welding device for remotely controlling welding power supply settings is provided. One embodiment of the welding device includes a welding pendant having a control panel configured to control a plurality of settings of a welding power supply. The control panel is not part of the welding power supply and the plurality of settings includes a welding current output by the welding power supply. The welding pendant also includes a welding power input configured to receive welding power and data from the welding power supply via a welding power cable. The welding power is combined with the data such that the data is provided over the welding power cable.