Wireless Control Of A Welding Machine

Description

Abstract

A welding machine for welding an object may include a microprocessor to control the operation of the welding machine; a wireless remote controller to wirelessly control the welding machine and a transceiver to convert the wireless remote controller with the microprocessor.

Description

FIELD OF THE INVENTION

• [0001]

The present invention relates generally to welding machines and, more particularly, to a method and apparatus for remotely and wirelessly controlling operation of a power source of a welding-type system.

BACKGROUND

• [0002]

MIG welding, formerly known as Gas Metal Arc Welding (GMAW), combines the techniques and advantages of TIG welding’s inert gas shielding with a continuous, consumable wire electrode. An electrical arc is created between the continuous, consumable wire electrode and a workpiece. As such, the consumable wire functions as the electrode in the weld circuit as well as the source of filler metal. MIG welding is a relatively simple process that allows an operator to concentrate on arc control. MIG welding may be used to weld most commercial metals and alloys including steel, aluminum, and stainless steel. Moreover, the travel speed and the deposition rates in MIG welding may be much higher than those typically associated with either Gas Tungsten Arc Welding (TIG) or Shielded Metal Arc Welding (stick) thereby making MIG welding a more efficient welding process. Additionally, by continuously feeding the consumable wire to the weld, electrode changing is minimized and as such, weld effects caused by interruptions in the welding process are reduced. The MIG welding process also produces very little or no slag, the arc and weld pool are clearly visible during welding, and post-weld clean-up is typically minimized. Another advantage of MIG welding is that it can be done in most positions which can be an asset for manufacturing and repair work where vertical or overhead welding may be required.

• [0003]

A wire feeder is operationally connected to the power source and is designed to deliver consumable wire to a weld. To further enhance the operability of the wire feeder of a MIG welding system, known welding systems have connected the power source and the wire feeder to one another across a dedicated control cable that is in addition to a dedicated weld cable such that control signals defining the operational parameters of the power source are transmitted or fed back from the wire feeder to the power source, generally referred to as remote control.

• [0004]

One type of remote control device is used to regulate the operational welding parameters, and switch the welding power source output ON and OFF as well as change the power source mode via a pendant that connects to the power source by a multi-conductor cable. A wire feeder is connected to a power source by a control cable that includes a 14-pin connector. The cable used to transmit operational information to, and in some cases, from the power source may incorporate 2 to 14 conductors depending on how many functions are to be controlled. Separately connected between the power source and wire feeder is a high voltage weld cable that delivers welding power to the wire feeder and creates a voltage potential between an electrode and a workpiece.

• [0005]

A significant drawback to this control cable-based scheme is that the control cable is typically fragile relative to the welding cables designed to carry high currents at high voltages. Welding machines are commonly used at construction sites or shipyards where it is not uncommon for the welding machines to be periodically relocated or surrounded by other mobile heavy equipment operating in the same area. As such, the remote control cable can become damaged by being crushed or snagged from contact with surrounding machines and/or traffic. This can cause damage to the wire feeder and/or the welding power source if internal power conductors become shorted to signal leads that are connected to sensitive signal level circuitry (See U.S. Pat. No. 7,902,484).

• [0006]

MIG and TIG welders use inert gas to remove the oxygen from the arc meal metal, to avoid the oxidation, consequently, this kind of welder is normally used indoor because the wind removes the inert gas and oxidation takes place, having defective welds.

• [0007]

In some applications, the welder operator may not have easy access to the welder machine.

EXAMPLES

• [0008]

Building construction, Oil platforms, Derricks, oil field, Plants, etc. and use mainly rod electrode, because it is outdoor job.

• [0009]

When a welder is working on a pipeline normally needs a helper because the helper changes the settings on the welder machine when the welder indicates, this settings depends of work position. It would be desirable to eliminate the need for the helper.

SUMMARY

• [0010]

A welding machine for welding an object may include a microprocessor to control the operation of the welding machine; a wireless remote controller to wirelessly control the welding machine and a transceiver to convert the wireless remote controller with the microprocessor.

• [0011]

The transceiver is to transmit and receive RF signal and, data and commands

• [0012]

The microprocessor may provide automatic control of the welding machine.

• [0013]

The remote control may only can set settings present on the welder machine front panel, like: start, stop, select current, select digging and so on, desired by the operator. One can see it like an extent of the welder machine FRONT PANEL plus some practical functionality like pipe mode and automatic start and stop engine.

• [0014]

The microprocessor may provide pipe mode control of the welding machine to replace the action of the welder helper that may include increasing or decreasing the current when the operator needs to do it, according to the welder position.

• [0015]

The microprocessor may control the welding current by pulse width modulation when is operating in an electric welder machine field current controlled.

• [0016]

The microprocessor may control an AC load sensor to start the engine when power is demanded.

• [0017]

The automatic control may set a predetermined time to stop the welding machine when the machine is in idle state.

• [0018]

The automatic control may start the welding machine when power is demanded.