Welding Power Supply with Robot Detector for Handheld and Robotic Modes
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Solution Overview
Problem
Existing welding systems require reconfiguration when switching between robotic and handheld modes, and lack a single power supply that can seamlessly operate with both robotic and handheld systems simultaneously or sequentially.
Innovation Solution
A welding system with a controller and robot detector that automatically determines the connected device, using a 'smart' cord with multiple connectors to activate either a hand-held module or robot interface, allowing for seamless operation as either a robotic or handheld welder, and includes a method to control welding parameters based on detected connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a welding system is designed for robotic welding, then automation capability is improved, but compatibility with hand-held welding deteriorates
Solution Approach 1:
The welding power supply is designed with a universal interface that can detect and adapt to both robotic and hand-held welding configurations. The system includes a robot detector that automatically identifies the connected device type and switches between robot interface and hand-held module accordingly, allowing a single power supply to serve multiple welding modes without requiring separate dedicated systems.
2Ease of operation
If a welding system is designed for hand-held welding, then ease of operation is improved, but automation capability deteriorates
Solution Approach 1:
The power supply incorporates both hand-held module and robot interface within a single system. When a hand-held welding gun is detected, the system activates the hand-held module with appropriate controls and parameters. When a robot is detected, it switches to robot interface mode, maintaining full automation capability while preserving hand-held operation readiness.
3Reliability
If separate power supplies are used for robotic and hand-held welding, then specialization is improved, but system complexity deteriorates
Solution Approach 1:
The patent combines previously separate robotic welding power supply and hand-held welding power supply into a single integrated system. The unified power supply includes detection circuitry, multiple operational modes, and automatic switching capability, reducing the total number of devices from two separate power supplies to one while maintaining specialized functionality for both welding types.
4Reliability
If reconfiguration is required when switching between robotic and hand-held modes, then mode-specific optimization is improved, but ease of operation deteriorates
Solution Approach 1:
The welding power supply includes an automatic detection and switching system that identifies whether a robot or hand-held gun is connected and automatically configures the appropriate operational mode. The robot detector monitors connector status and triggers automatic mode switching between robot interface and hand-held module without requiring manual user intervention or system reconfiguration, thereby maintaining mode-specific optimization while eliminating the burden of manual switching.
Data Source
AI summary
A method and apparatus for automatic or hand held welding is disclosed and includes a power circuit with a controller. The controller has a robot detector. A hand-held module and a robot interface are responsive to the robot detector. A user interface provides welding parameter setpoints to the hand held module when the robot detector detects a gun, or the absence of a robot. When a gun is present, the trigger on the gun is used to cause power to be provided, and/or welding parameters are set by the user interface on the system. When a robot is present the robot controls the process. The detection is done at start-up, or at other times.