Wire Feeder Wireless Control via Power Cable
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Solution Overview
Problem
Existing welding-type systems face delays and inefficiencies due to the need for operators to physically travel to remote power supplies to adjust settings, and current remote control solutions are prone to cable damage and lack flexibility in adjusting output for varying workpiece thickness and fit-up, with high current DC contactors being large, heavy, and costly.
Innovation Solution
A welding-type system that incorporates a wireless network interface in a wire feeder to receive commands and convert them for transmission via a power delivery cable to a power supply, allowing remote monitoring and control of power levels and wire feed speeds, using a hybrid network of wireless and power cable communications to extend connectivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate multi-conductor cable is used to connect the remote control device to the power supply, then the power source settings can be changed remotely, but the cable is fragile and may become shorted, increasing the risk of failure
Solution Approach 1:
The patent combines the control signal transmission and power delivery functions into a single existing power cable. The wire feeder's control circuitry modulates control signals onto the power cable that already connects the power supply to the wire feeder, eliminating the need for a separate fragile control cable while maintaining reliable communication.
Solution Approach 2:
The power cable is made multi-functional by enabling it to carry both power delivery and control signals simultaneously. The control circuitry in the wire feeder detects and processes control signals that are superimposed on the power cable, allowing the single cable to serve dual purposes: powering the wire feeder and transmitting control commands.
2Ease of operation
If additional cables are used for remote control, then control functionality is achieved, but the weight to be moved during operation increases
Solution Approach 1:
The control signals are merged into the existing power cable transmission, eliminating the need for additional separate control cables. This reduces the total cable weight that must be handled and moved during welding operations while preserving full control functionality.
3Extent of automation
If high current DC contactors are used to de-energize welding circuits, then the welding circuits can be controlled, but the contactors are large, heavy, and costly
Solution Approach 1:
The patent replaces the mechanical high current DC contactor system with an electronic control circuitry system. The control circuitry in the wire feeder uses electronic signal processing to detect and respond to control signals, eliminating the need for large, heavy mechanical contactors while achieving the same welding circuit control functionality.
4Extent of automation
If voltage following or sensing using an internal contactor is used, then the welding circuits can be controlled, but there is no convenient way to adjust the output to compensate for changes in workpiece thickness and fit up
Solution Approach 1:
The control circuitry continuously monitors welding parameters and workpiece conditions, receiving control signals that indicate required adjustments for workpiece thickness and fit-up variations. The system uses this feedback to dynamically adjust power supply output and wire feed speed, providing real-time compensation for changing welding conditions.
Solution Approach 2:
The system transitions from static welding parameters to dynamic, real-time adjustable parameters. The control circuitry enables continuous adjustment of power output and wire feed speed based on incoming control signals, allowing the welding process to adapt dynamically to varying workpiece thickness and fit-up conditions throughout the welding operation.
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
Enables operators to control welding parameters remotely without leaving the workpiece, reducing delays and improving efficiency, while providing a robust and flexible solution that maintains connectivity even in areas with line-of-sight issues or physical obstructions, reducing the risk of cable damage and the need for large, heavy contactors.
Implementation Method 1
a wired transceiver configured to transmit the converted wireless command across a power delivery cable to the power supply
Implementation Method 2
a power supply. The power supply includes a wired transceiver configured to receive commands from a wire feeder through a power cable through which the power supply supplies power to the wire feeder
Data Source
AI summary
A welding-type system includes a wireless network interface configured to connect a wire feeder or power supply to a wireless network. The wireless network interface is also configured to receive a wireless command in a first format. The wireless command is configured to control the power supply. Moreover, the wireless network interface is configured to convert the wireless command from the first format to a second format. The welding-type system also includes a wired transceiver configured to transmit the converted wireless command across a power delivery cable to the power supply. Furthermore, the welding-type system includes power terminals configured to receive power from the power supply at a level based at least in part on the transmitted wireless command.