Welding Torch LED Indication for On-Handle Schedule Visibility
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Solution Overview
Problem
Conventional methods for presenting welding settings and parameters in welding systems are cumbersome, inefficient, and costly, often requiring operators to view changes at the welding power source, which may not be visible from the operator's location, leading to unintended parameter changes.
Innovation Solution
The implementation of a welding-type torch with indication components, such as light-emitting diodes (LEDs), that provide visual feedback of welding parameters directly on the torch, allowing operators to view parameter settings without altering the existing connector structure, enabling convenient and cost-effective parameter adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If welding parameters are indicated at the power source, then parameter information is provided, but the indication is not viewable from the operator's welding location
Solution Approach 1:
The patent introduces a new spatial dimension for parameter indication by placing LEDs on the torch handle near the operator's hand, rather than keeping indications only at the power source. This dimensional relocation allows simultaneous viewing of parameters at both locations, resolving the visibility-convenience contradiction.
2Loss of information
If indication components are added to the torch, then parameter visibility at the welding location is improved, but connector structure complexity increases
Solution Approach 1:
The patent makes the existing connector pins multi-functional by using them for both their original electrical connection purpose and as signal carriers for LED indication. This allows the torch to display parameters without adding dedicated indication connector structures, maintaining connector simplicity while achieving improved visibility.
Solution Approach 2:
The existing connector infrastructure serves dual purposes: it provides both power/electrical connection and carries indication signals to the torch. The system uses its own existing structures (connector pins) to provide the indication function, avoiding the need for separate dedicated indication connectors.
3Loss of information
If new indication system is implemented, then parameter feedback is improved, but system cost increases
Solution Approach 1:
The patent reuses existing connector pins for dual purposes (electrical connection and indication signaling), eliminating the need for separate dedicated indication connectors. This multi-functionality approach reduces component count and system cost while maintaining improved parameter feedback capability.
Solution Approach 2:
The existing connector pins act as intermediaries that transfer both power signals and indication signals between the power source and torch. By using these existing intermediary structures for dual purposes, the patent avoids the cost of implementing a completely separate indication communication infrastructure.
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 allows for efficient and cost-effective indication and adjustment of welding parameters directly on the welding torch, enhancing operator convenience and reducing the risk of unintentional changes by maintaining compatibility with existing connectors.
Implementation Method 1
indication components, such as light-emitting diodes (LEDs), that provide visual feedback of welding parameters directly on the torch
Data Source
AI summary
Systems and methods are provided for indicating schedules in welding-type torches. A welding-type system may comprise a welding-type power source, a welding-type torch, driven by the welding-type power source, and a welding-type connector configured for connecting the welding-type power source to the welding-type torch. The welding-type torch may comprise one or more indication components configured for providing, to a user of the welding-type system, indications relating to at least one of operations of the welding-type torch, status of welding-type operations, or welding-type parameters. The one or more indications comprise an indication of a present value of a particular welding-type parameter that pertains to configuration of the welding-type power source; and the one or more indication components are configured to provide the indication of present value of the particular welding-type parameter without requiring a change to structure of the welding-type connector.