Wireless Weld Schedule Selection for Remote Power Supply Control
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Solution Overview
Problem
Conventional welding power supplies lack remote control capabilities, leading to suboptimal weld settings due to distance constraints, resulting in inefficient welding operations.
Innovation Solution
A remote device with a user interface and control circuitry that allows for the selection and transmission of weld schedules and operational settings to a welding power supply, enabling remote control and optimization of welding parameters such as voltage, current, and wire feed speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the control panel is located at the welding power supply location, then the operator can directly access controls, but the operator cannot remotely adjust weld settings when at a distance from the power supply
Solution Approach 1:
The control system is divided into two separate components: a control panel and a remote device. The control panel remains at the welding power supply location while the remote device can be positioned anywhere within wireless communication range, allowing operators to separate the control function from the power supply location.
Solution Approach 2:
A wireless communication system acts as an intermediary between the control panel and the remote device. The remote device transmits control signals wirelessly to the control panel, enabling remote operation without requiring a physical connection between the operator and the power supply.
2Ease of operation
If the operator is at a distance from the welding power supply, then the operator has better mobility, but the operator cannot make real-time adjustments to weld settings
Solution Approach 1:
The wireless communication system enables real-time transmission of control signals from the remote device to the control panel, eliminating the time delay associated with physical movement to the control panel while maintaining immediate responsiveness to welding conditions.
Solution Approach 2:
The system allows dynamic changing of welding parameters (voltage, current, wire feed speed) through wireless communication, enabling real-time adjustment of weld settings without requiring the operator to be physically present at the power supply location.
3Productivity
If manual adjustments are required for changing weld schedules, then the control system is simple, but the welding efficiency decreases due to repeated manual interventions
Solution Approach 1:
The remote device serves as an intermediary that enables efficient schedule changes without requiring physical presence at the control panel. Operators can switch between weld schedules and adjust parameters remotely, significantly improving welding efficiency while maintaining a relatively simple control system architecture.
Data Source
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AI summary
Systems and methods for remote control of a weld schedule of a welding power supply are disclosed. In some examples, a remote device is provided for monitoring or controlling the welding power supply, which controls and delivers power to one or more welding tools (e.g., a welding torch) and/or accessories (e.g., a wire feeder). The remote device includes a user interface to receive one or more inputs, which are provided to a control circuitry configured to transmit signals to or receive signals from the welding power supply via a remote transceiver. In some examples, the signals include data corresponding to one or more weld schedules.