Welding Torch Schedule Selection With On-Torch LED Feedback
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Solution Overview
Problem
Conventional methods for setting and adjusting welding parameters in welding-type systems are cumbersome, inefficient, and prone to unintentional changes, often requiring users to move to the welding equipment for parameter adjustments and lacking clear indications on the torch.
Innovation Solution
A welding-type system that allows for the direct indication of welding schedules and parameters on the torch using feedback elements, such as LEDs, while maintaining compatibility with existing connectors, and enabling convenient parameter setting through enhanced input mechanisms like dual schedule solutions and trigger-based controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If welding parameters are set directly through welding equipment, then parameter setting capability is improved, but user convenience deteriorates as users must move from welding location
Solution Approach 1:
A wireless communication module serves as an intermediary between the torch and the welding equipment control interface. The module receives welding parameter settings wirelessly from the welding equipment and displays them locally on the torch, allowing operators to view and adjust parameters at the welding location without physically moving to the equipment.
2Loss of information
If feedback elements are added to the torch, then parameter indication capability is improved, but device complexity increases
Solution Approach 1:
LED indicators are used as feedback elements on the torch because they are inexpensive, reliable, and require minimal circuitry. These simple visual indicators provide clear parameter status information without adding significant complexity to the torch structure, making the added complexity worthwhile given their low cost and simplicity.
3Productivity
If trigger-based control is implemented, then operation efficiency is improved, but risk of unintentional changes increases
Solution Approach 1:
The system uses periodic or sequential activation of the trigger button to cycle through different welding schedules. Each press of the trigger advances to the next schedule in a predetermined sequence, allowing efficient selection of multiple parameters through repeated simple actions rather than complex adjustments, while the sequential nature reduces accidental changes compared to continuous adjustment modes.
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
Facilitates efficient and accurate setting of welding parameters directly on the torch, reducing the risk of unintentional changes and enhancing user convenience without altering existing connector layouts.
Implementation Method 1
A welding-type torch is disclosed with which double clicking the torch trigger switch changes the welding parameters to the next highest schedule number. The selected schedule is indicated by a light emitting diode.
Data Source
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AI summary
Systems and methods are provided for selecting welding schedules in welding-type torches. A welding-type torch (30) configured for use during welding-type operations, with the welding-type torch comprising an input device (232, 234) configured for setting a welding-type parameter, such as welding schedules, associated with a welding-type device (12) that is used in conjunction with the welding-type torch during the welding-type operations. The welding-type device may be a welding-type power source. The welding-type torch is connected to the welding-type device via a welding-type connector (14), with the setting of the welding-type parameter occurring via the welding-type connector and without requiring a change to structure of the welding-type connector (14). The welding-type parameter is set to one of a plurality of available values, with the input device (232, 234) causes setting the welding-type parameter to a specific value from the plurality of available values only in response to receiving a corresponding specific input associated with that value.