The invention described herein pertains generally to a system and method that incorporates an illumination system with an engine driven welder, and in particular, a lighting element that uses power from the engine driven welder to provide illumination of an environment.
Frequently, welding is required where supply power may not be readily available. As such, the welding power supply may be an engine driven welding power supply incorporating a generator. The generator may supply power to the welder as well as to other power tools as may be needed on site. As different applications require different versions of welders and power tools, the trailer may be designed to carry one of many different types of welding power supplies.
Traditional welding-type apparatus can be broken into two basic categories. The first category receives operational power from transmission power receptacles, also known as static power. The second is portable or self-sufficient, stand alone welders having internal combustion engines, also known as rotating power. While in many settings conventional static power driven welders are preferred, engine driven welders enable welding-type processes where static power is not available. Rotating power driven welders operate by utilizing power generated from engine operation. As such, engine driven welders and welding-type apparatus allow portability and thus fill an important need.
Static powered welders initiate the weld process by way of a trigger on a hand-held torch or with an electrically charged stick connected to a charged electrode.
Rotating power driven welders operate similarly, as long as the engine is running. If the engine is shut down, there is typically no residual power to create an arc. To once again weld, the engine must be started and run at operational speed to produce the arc. Therefore, it is simply not possible to manually start and stop the engine between each and every break in the welding process. Further, even during longer periods, operators may find it easier to let the engine run because of distance to the engine, a misconception that it is better for the engine, or just out of habit.
In accordance with the present invention, there is provided a welding device that includes a motor-driven welder assembly including a motor that is a power source for the welder device to perform a welding operation and a circuit component that electrically isolates and converts the power source to a first voltage used for controlling the welding operation. The welding device can further include a converter component that converts the first voltage to a second voltage. The welding device can further include a lighting element that uses a portion of the second voltage as a light power source to illuminate the lighting element, wherein the lighting element illuminates based on a switch.
In accordance with the present invention, there is provided a method that includes at least the following steps: utilizing at least one of a motor or an energy storage device to supply a voltage for use with a welding operation; receiving the voltage; reducing the voltage to an isolated second voltage, wherein the isolated second voltage is less than the voltage from the motor; and utilizing the isolated second voltage to power a lighting element.
In accordance with the present invention, there is provided a welding device that includes at least the following: a motor-driven welder assembly including a motor that is a power source for the welder device to perform a welding operation; a circuit component that electrically isolates and converts the power source to a first voltage used for controlling the welding operation; a converter component that converts the first voltage to a second voltage; a housing for containing the lighting element; an energy storage device affixed to the housing, wherein the energy storage device stores a portion of the second voltage; a support member coupled to the housing, wherein the support member is detachable from a housing of the welding device; and means for emitting light using the portion of the second voltage as a primary power source.
These and other objects of this invention will be evident when viewed in light of the drawings, detailed description and appended claims.
The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
Embodiments of the invention relate to methods and systems that generally relate to converting a voltage generated by a power source of a welding device to a second voltage, wherein the second voltage is lower than the first voltage and is used to power a lighting element. For instance, a first circuit component can convert a voltage from the power source of the welding device, wherein the voltage is used for control of a welding operation. An illumination system can receive a portion of the voltage or convert a portion of the voltage for use as a light power source to power a lighting element to provide illumination to an environment. For example, a motor of a welding device can generate a voltage and such voltage can be converted for control of a welding operation. Additionally, a converter component can be configured to convert and isolate the voltage to a second voltage that is used as a light power source for the lighting element. In another embodiment, the lighting element can include an energy storage device that stores a portion of the second voltage.
The subject innovation can be used with any suitable engine-driven welder, engine-driven welding system, engine-driven welding apparatus, a welding system powered by an engine, a welding system powered by a battery, a welding system powered by an energy storage device, a hybrid welder (e.g., a welding device that includes an engine driven power source and an energy storage device or batter), or a combination thereof. It is to be appreciated that any suitable system, device, or apparatus that can perform a welding operation can be used with the subject innovation and such can be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. The engine driven welder can include a power source that can be used in a variety of applications where outlet power is not available or when outlet power will not be relied on as the sole source of power including portable power generation, backup power generation, heating, plasma cutting, welding, and gouging. The example discussed herein relates to welding operations, such as, arc welding, plasma cutting, and gouging operations. It is to be appreciated that a power source can generate a portion of power, wherein the portion of power is electrical power. It is to be appreciated that “power source” as used herein can be a motor, an engine, a generator, an energy storage device, a battery, a component that creates electrical power, a component that converts electrical power, or a combination thereof. By way of example and not limitation,
The housing 112 of the welding-type device 100 also houses an internal combustion engine. The engine is evidenced by an exhaust port 130 and a fuel port 132 that protrude through the housing 112. The exhaust port 130 extends above the top panel 122 of the housing 112 and directs exhaust emissions away from the welding-type device 100. The fuel port 132 preferably does not extend beyond the top panel 122 or side panel 124. Such a construction protects the fuel port 132 from damage during transportation and operation of the welding-type device 100.
Referring now to
The welding arc or cutting arc is generated by the power source by conditioning raw power received from an interchangeable energy storage device 226. In a preferred embodiment, energy storage device 226 is a battery. Energy storage device 226 is interchangeable with similarly configured batteries. Specifically, energy storage device 226 is encased in a housing 228. Housing 228 is securable to the housing of welding device 210 thereby forming welding-type apparatus 205. Specifically, energy storage device 226 is secured to power source 210 by way of a fastening means 230. It is contemplated that fastening means 230 may include a clip, locking tab, or other means to allow energy storage device 226 to be repeatedly secured and released from power source 210.
The motor 425 and energy storage device 430 may be operated individually or in tandem to provide electricity for the welding operation and any auxiliary operations performed by hybrid welder 400. For example, individual operation may include operating the motor 425 and supplementing the power from the motor 425 with power from the energy storage device 430 on an as needed basis. Or supplying power from the energy storage device 430 alone when the motor 425 is offline. Tandem operation may also include combining power from motor 425 and energy storage device 430 to obtain a desired power output. According to one aspect of the invention, a welder 400 may be provided with a motor having less power output than ordinarily needed, and energy storage device 430 used to supplement the power output to raise it to the desired power output level. In an embodiment, a motor with no more than 19 kW (25 hp) output may be selected and supplemented with six 12 volt batteries. Other combinations of motor output may be used and supplemented with more or less power from energy storage device. The above example, therefore, is not limiting.
Energy storage device 430 may be any alternative power source including a secondary generator, kinetic energy recovery system, or, as shown, one or more batteries 431. In an embodiment, six 12 volt batteries 431 are wired in series to provide power in connection with motor-driven welder assembly 420. Batteries 431 shown are lead acid batteries. Other types of batteries may be used including but not limited to NiCd, molten salt, NiZn, NiMH, Li-ion, gel, dry cell, absorbed glass mat, and the like.
The best mode for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time of the filing of this patent application. The examples and figures are illustrative only and not meant to limit the invention, which is measured by the scope and spirit of the claims. Referring now to the drawings, wherein the showings are for the purpose of illustrating an exemplary embodiment of the invention only and not for the purpose of limiting same,
Turning to
Welding device 500 further includes first circuit component 520 that is configured to isolate and convert the voltage generated by power source 510 for use with a welding operation. For example, first circuit component 520 can include any suitable circuitry that converts power source 510 for use with a welding operation. For instance, first circuit component 520 can convert a first voltage from power source 510 to a control voltage that is used for controlling a welding operation, wherein the first voltage is greater than the control voltage. By way of example and not limitation, first circuit component 520 can be an isolation stepdown circuit. Moreover, it is to be appreciated that first circuit component 520 can be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. For example, although welding device 500 is illustrated with first circuit component 520, any suitable number of circuits can be utilized by the subject innovation.
First circuit component 520 can be configured to isolate and convert the voltage from power source 510. First circuit component 520 can further condition voltages from power source 510 so as to reduce effects from power source 510. By way of example and not limitation, conditioning can relate to a filtering of a signal, a noise reduction of a signal, isolation of a signal, and the like. For instance, a conditioning of a signal can be performed by, but not limited to, an optical coupler, a transformer, among others. It is to be appreciated and understood that first circuit component 520 can be a stand-alone component (as depicted), incorporated into converter component 530, incorporated into illumination system 525, or a combination thereof
Illumination system 525 can include a converter component 530 that can receive a portion of the first voltage and convert such first voltage into a second voltage, wherein the second voltage is utilized by illumination system 525. It is to be appreciated and understood that converter component 530 can be a stand-alone component (as depicted), incorporated into first circuit component 520, or a combination thereof. Illumination system 525 utilizes the second voltage as light power source 540 to provide lighting or illumination to an environment (discussed in more detail below). Converter component 530 can provide a conversion of a portion of the first voltage and at least one of an isolation of the second voltage or a conditioning of the second voltage. By way of example and not limitation, conditioning can relate to a filtering of a signal, a noise reduction of a signal, isolation of a signal, and the like. For instance, a conditioning of a signal can be performed by, but not limited to, an optical coupler, a transformer, among others. By way of example, converter component 530 can be an isolation stepdown circuit.
Lighting element 550 is powered by light power source 540 that has voltage provided by the second voltage as discussed above. By way of example and not limitation, lighting element 550 can be a bulb, a filament bulb, a Light Emitting Diode (LED), a fluorescent, a halogen, a Compact Fluorescent Lamp (CFL), among others. Lighting element 550 can be integrated into welding device 500, detachable from welding device 500, attached to welding device 500, a combination thereof, and the like. For instance, lighting element 550 can provide illumination to an environment based on being a portable and detachable. This portability allows lighting element 550 to reach areas that welding device 500 cannot. In another embodiment, a portable stand is stored with welding device 500 such that the portable stand can allow lighting element 550 to be positioned in an environment. In still another embodiment, lighting element 550 can be incorporated into an area of a housing of welding device. For instance, lighting element 550 can be affixed to a front of welding device 500, a rear of welding device 500, a side of welding device 500, or a combination thereof. In still another embodiment, lighting element 550 can be adjustable for user-specified aiming of a light or an illumination of an environment.
For example, welding device 600 can include first circuit component 520 to convert voltage from power source 510 for use with control of a welding operation on a workpiece. For instance, a hardware link board can be used to convert and isolate voltage from power source 510 to use for the welding operation or control thereof. In such example, the hardware link board can step down voltage from power source 510 to 40 volts. In an example, converter component 530 can convert the 40 volts to a second voltage that is lower than 40 volts and use such second voltage with illumination system 525. In still another embodiment, the hardware link board can incorporate converter component 530 to provide the second voltage.
Illumination system 525 can include switch 610 that activates or deactivates lighting element 550. For instance, switch 610 can control electric flow (e.g., second voltage) between light power source 540 and lighting element 550. It is to be appreciated that the manner of how switch 610 activates or deactivates the second voltage to lighting element 550 can be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. By way of example and not limitation, switch 610 can be a button, a lever, a slider, a touchscreen, a touch-activated button, a toggle switch, a knob, a voice activated device, a motion sensor, a pressure sensor, and the like. In an embodiment, switch 610 can be a light sensor that detects an amount of brightness for an environment of welding device 500, wherein lighting element 550 illuminates based on the amount of brightness for the environment
Lighting element 540 can be incorporated into housing 620. Housing is configured to contain lighting element 540. For instance, housing 620 can be fabricated from any suitable material such as, but not limited to, a plastic, a steel, a metal, a polymer, a combination thereof, and the like.
Further, housing 620 can contain energy storage device 630. Energy storage device 630 can store a portion of the second voltage to allow for a portable use of lighting element 550. For instance, lighting element 550 can be electrically decoupled from welding device 600 and/or light power source 540, wherein a stored portion of the second voltage within energy storage device 630 is used to illuminate lighting element 550. It is to be appreciated that for the sake of brevity any components or circuitry that provides use of stored second voltage in energy storage device 630 are not illustrated but one of sound engineering judgment can chose circuitry and/or components to allow portability and decoupling use of lighting element 550.
Welding device 700 can further include cord holder 720 that can contain, house, or store a portion of cord 710. In a particular embodiment, cord holder 720 can include a spring-loaded or mechanical mechanism that allows for automatic winding or retraction of a portion of cord 710. Although cord 710 and cord holder 720 are depicted, it is to be appreciated and noted that a cordless embodiment is also included with the subject disclosure as discussed in
Support member 730 can couple to housing 620 that contains lighting element 550. It is to be appreciated that support member 730 can couple directly to lighting element 550 if no housing 620 is utilized. In another embedment, housing 620 can be utilized as support member 730. Support member 730 provides a location for a user to handle, grip, hold, or position lighting element 550. For instance, support member 730 can be an ergonomic shape that conforms to a portion of a hand, a palm, a finger, and the like. In another embodiment, support member 730 can be shaped to affix to a mechanical device such as, but not limited to, a welding torch, a welding helmet, a welding visor, a clamp, among others. Support member 730 can further provide detachment from welding device 700 and in particular a housing of welding device 700. For instance, in either a corded or cordless use, support member 730 can be used to holster lighting element 540 to a portion of welding device 700 and also be used to holster on a stand for positioning of a desired location for illumination. In another embodiment, support member 730 can be interchangeably coupled to various locations on welding device 700 such as, but not limited to, a front of welding device 700, a side of welding device 700, a rear of welding device 700, a corner of welding device 700, a top of welding device 700, a bottom of welding device 700, among others.
In an embodiment, the lighting element is at least one of a bulb, a filament bulb, a Light Emitting Diode (LED), a fluorescent, a halogen, or a Compact Fluorescent Lamp (CFL). In an embodiment, the converter component isolates and conditions the second voltage converted from the first voltage. In an embodiment, the welding device can include a housing for containing the lighting element. In the embodiment, the welding device can include an energy storage device affixed to the housing for containing the lighting element, wherein the energy storage device stores a portion of the second voltage. In the embodiment, the welding device can include a support member coupled to the housing, wherein the support member is detachable from a housing of the welding device. In an embodiment, the support member is shaped to conform to a portion of a hand of a user.
In an embodiment, the welding device can include a housing of the welding device that includes an energy storage device to store a portion of the second voltage. In an embodiment, the welding device can include a cord that connects at least the lighting element to the light power source. In the embodiment, the welding device can include a cord holder that stores a portion of the cord. In an embodiment, the cord holder includes a switch that automatically retracts and winds a portion of the cord. In an embodiment, the welding device can include a light sensor that detects an amount of brightness for an environment of the welding device, wherein the lighting element illuminates based on the amount of brightness for the environment. In the embodiment, the welding device can include an energy storage device that is an additional power source for the welding device to perform the welding operation and a switch component that selects between the energy storage device and the motor. In an embodiment, the converter component converts a voltage stored in the energy storage device to the second voltage used to illuminate the lighting element.
In view of the exemplary devices and elements described supra, methodologies that may be implemented in accordance with the disclosed subject matter will be better appreciated with reference to the flow charts and/or methodologies of
Sequentially, the following occurs as illustrated in the decision tree flow diagram 800 of
In an embodiment of the method, the lighting element is at least one of a bulb, a filament bulb, a Light Emitting Diode (LED), a fluorescent, a halogen, or a Compact Fluorescent Lamp (CFL). In an embodiment, the method can include storing a portion of the second voltage in an lighting element energy storage device and using the portion of the second voltage in the lighting element energy storage device to illuminate the lighting element. In an embodiment, the method can include detected a brightness of an environment and activating the lighting element based on the detected brightness. In an embodiment, the method can include retracting a portion of a cord connected between the lighting element and the welding device based upon at least one of a mechanical switch.
While the embodiments discussed herein have been related to the systems and methods discussed above, these embodiments are intended to be exemplary and are not intended to limit the applicability of these embodiments to only those discussions set forth herein. The control systems and methodologies discussed herein are equally applicable to, and can be utilized in, systems and methods related to arc welding, laser welding, brazing, soldering, plasma cutting, waterjet cutting, laser cutting, and any other systems or methods using similar control methodology, without departing from the spirit or scope of the above discussed inventions. The embodiments and discussions herein can be readily incorporated into any of these systems and methodologies by those of skill in the art. By way of example and not limitation, a power supply as used herein (e.g., welding power supply, among others) can be a power supply for a device that performs welding, arc welding, laser welding, brazing, soldering, plasma cutting, waterjet cutting, laser cutting, among others. Thus, one of sound engineering and judgment can choose power supplies other than a welding power supply departing from the intended scope of coverage of the embodiments of the subject invention.
The above examples are merely illustrative of several possible embodiments of various aspects of the present invention, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, circuits, and the like), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component, such as hardware, software, or combinations thereof, which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the invention. In addition although a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in the detailed description and/or in the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”
This written description uses examples to disclose the invention, including the best mode, and also to enable one of ordinary skill in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
The best mode for carrying out the invention has been described for purposes of illustrating the best mode known to the applicant at the time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and merit of the claims. The invention has been described with reference to preferred and alternate embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
This application claims the benefit of priority to U.S. Provisional Application Ser. No. 61/876,791, filed Sep. 12, 2013, and entitled “LIGHT SYSTEM FOR ENGINE DRIVEN WELDER.” The entirety of the aforementioned application is incorporated herein by reference.
Number | Date | Country | |
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61876791 | Sep 2013 | US |