Welding Sequence Control via Downloadable State Tables
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Solution Overview
Problem
Current welding system sequence controllers are difficult to modify and adapt, requiring firmware revisions and hardware reconfiguration, limiting user flexibility in refining welding processes and adapting to different operations.
Innovation Solution
A reprogrammable sequence control system with a processing component, sequence control program, and state table files that allow users to easily modify or download table files without recompiling firmware or software, enabling straightforward adjustment of welding parameters and operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional firmware-based sequence controllers are used, then system reliability is maintained, but adaptability and ease of modification deteriorate
Solution Approach 1:
The patent implements a state table file that serves as a configurable copy of the control logic, separate from the main firmware. This table file can be easily modified and downloaded without changing the core firmware, allowing users to adapt welding sequences without complex recompilation processes.
Solution Approach 2:
The system transitions from static firmware-based control to dynamic, reconfigurable control through state table files. The controller can load different state table files to adapt to various welding operations, making the system dynamically adaptable without hardware changes or firmware recompilation.
2Ease of operation
If state table files are made easily modifiable, then ease of operation improves, but system reliability may deteriorate
Solution Approach 1:
The patent introduces an intermediary validation process between user modifications and system execution. The controller validates the state table file format and contents before loading, ensuring that user-friendly modifications do not compromise system reliability through invalid configurations.
3Ease of manufacture
If hardware reconfiguration is required for sequence changes, then manufacturing precision is maintained, but ease of manufacture deteriorates
Solution Approach 1:
The patent replaces mechanical hardware reconfiguration (jumpers, switches, wiring changes) with electronic software-based configuration through state table files. This substitution eliminates the time-consuming physical reconfiguration process while maintaining precise control over welding sequences.
Data Source
AI summary
Welding systems and sequence controllers therefor are presented for controlling components of a welding system during a welding operation. The sequence controller receives system inputs and provides control outputs to the system components, and includes a processing component, an executable sequence control program, and a state table file. The sequence control state table file includes a number of entries corresponding to welding operation states, where the individual entries comprise one or more instruction identifiers, instruction parameters, exit condition identifiers and corresponding next state identifiers. The sequence control program is executed according to the sequence controller inputs and according to the state table file to provide the sequence controller outputs, where the state table file can be easily modified or new state table files can be created and downloaded to the sequence controller to facilitate easy reconfiguration of a welding system.