Welding Torch Cryptographic Authentication Against Unauthorized Replacement

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Solution Overview

Problem

Competitors can replicate genuine manufacturer plasma cutting and welding torches, limiting the manufacturer's ability to sell consumables, as mechanical solutions to tie consumables to the torch do not prevent torch replacement.

Innovation Solution

Electronically locking welding or cutting torches to their corresponding power sources using cryptographic devices that communicate encryption keys and unlock codes, ensuring only genuine manufacturer torches can operate by employing fuse-protected circuitry and polynomial splines to prevent hardware duplication and ensure continuous authentication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If mechanical solutions are used to tie consumables to the torch, then consumable attachment is improved, but torch replacement prevention is insufficient

Engineering Contradiction:

Improveconsumable attachmentVSAvoidtorch replacement prevention

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces mechanical locking mechanisms with an electronic cryptographic authentication system. The torch and power source exchange encrypted messages and verify authentication codes, eliminating the need for physical locking mechanisms while providing more reliable torch replacement prevention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces cryptographic messages and authentication codes as intermediaries between the torch and power source. These digital intermediaries verify genuine manufacturer status and prevent unauthorized torch replacement more effectively than direct mechanical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If cryptographic authentication is implemented, then torch authentication is improved, but device complexity increases

Engineering Contradiction:

Improvetorch authenticationVSAvoidcryptographic system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent performs cryptographic key exchange and authentication code generation during initial torch replacement or first use. By completing the authentication setup in advance, the system avoids complex real-time cryptographic operations during normal operation, reducing operational complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses encrypted copies of authentication codes and cryptographic messages to verify torch authenticity. Instead of complex real-time verification, the system exchanges and verifies digital copies of authentication data, simplifying the authentication process while maintaining security.

Inventive Principle:

Principle #26Copying

3Reliability

If fuse protected circuitry is used, then hardware duplication prevention is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvehardware duplication preventionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses fuse protected circuitry that is inexpensive to manufacture but provides strong security. The fuse protection is a simple, low-cost component that permanently locks the cryptographic device, preventing hardware duplication while keeping manufacturing costs low.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the electrical state of the cryptographic device by blowing fuses to lock the hardware. This irreversible parameter change (from conductive to open circuit) prevents hardware duplication while using simple, well-understood manufacturing processes for fuse protection.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11554441B2Systems and methods providing a torch that presents as a genuine manufacturer torch to a power source

Publication Date: 2023.01.17 LINCOLN GLOBAL INC

AI summary

Embodiments of welding and cutting systems are disclosed. A welding or cutting system includes a power source to provide electrical power for a welding or cutting process. The system includes a torch having a cryptographic device, and is to be used with the power source during the process and communicate with the power source. The cryptographic device is configured to receive an encryption key seeded by the power source during first time power-on initialization of the welding power source or after the torch is replaced. The cryptographic device is configured to store an unlock code associated with the power source, generate an encrypted message, which includes the unlock code, based on the encryption key, and communicate the encrypted message to the power source. The power source is configured to cease further operation unless the power source determines the torch to be a genuine manufacturer torch based on the unlock code.