Welding Power Line Communication for Remote Pendant Control
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Solution Overview
Problem
Traditional multi-process welding systems require manual adjustments and frequent changes in welding processes and settings, which can be cumbersome and time-consuming, especially when working at a distance from the power source, necessitating frequent trips to connect or disconnect cables and adjust auxiliary devices.
Innovation Solution
A multi-process welding system with power line communication that allows bidirectional data transfer between a power supply and a pendant, enabling remote control of welding processes and powering of auxiliary devices, reducing the need for manual adjustments and cable changes through an auxiliary conduit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment and cable connection methods are used in traditional welding systems, then the welding process can be controlled, but the operator must frequently return to the power source making adjustments time-consuming and productivity reduced
Solution Approach 1:
The patent replaces manual mechanical adjustment at the power source with wireless communication technology. The pendant controller transmits control signals wirelessly to the welding power source, eliminating the need for physical cable connections and manual knob adjustments. This allows operators to change welding parameters remotely without returning to the power source, significantly improving both ease of operation and productivity
Solution Approach 2:
The patent introduces a wireless communication system as an intermediary between the pendant controller and the welding power source. This intermediary enables bidirectional data transfer, allowing the pendant to send control commands and the power source to transmit status information without physical connection, thereby resolving the contradiction between ease of operation and productivity
2Use of energy by moving object
If auxiliary devices are powered from outlets on the power supply, then auxiliary devices can be powered, but the location of power terminals requires operators to walk back considerable distances through complex work environments
Solution Approach 1:
The patent adds a wireless power transmission dimension to the system. Instead of relying solely on physical outlets located at the power source, the system enables power delivery through wireless communication channels. This allows operators to power auxiliary devices remotely without physically returning to the power source, significantly improving ease of operation while maintaining power delivery capability
3Adaptability or versatility
If welding processes are changed manually at the power source, then process switching can be accomplished, but frequent trips to the power source are necessary reducing time efficiency
Solution Approach 1:
The patent implements preliminary action by pre-programming multiple welding processes and parameters in the pendant controller's memory. Operators can select from pre-configured welding processes (MIG, TIG, Stick, etc.) without needing to manually adjust each parameter at the power source. This preliminary configuration enables rapid process switching through wireless commands, maintaining adaptability while dramatically reducing time loss
Data Source
AI summary
Various welding systems that provide communication over auxiliary or weld power lines are provided. The disclosed embodiments may include a multi-process welding power supply that is communicatively coupled to a pendant via an auxiliary conduit that facilitates the exchange of data and power between components of the welding system. In some embodiments, the pendant may also include auxiliary outlets that allow an operator to power auxiliary devices at the weld location. The disclosed embodiments further include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Embodiments are provided that also allow for bidirectional data communication over a power line in networked welding systems.