Embodiments of the present invention generally relate to systems and methods related to welding fume extraction, and more specifically to a control system that is configured to regulate a fume extraction flow rate for various welds in a welding sequence. Fume extraction systems are commonly utilized to remove welding fumes and particulate from a welder's breathing zone. Such systems generally require an operator manually setting a fume extraction flow rate (e.g., cfm) at a fume extraction system (e.g., a housing having a motorized fan) when performing a series of different welds. However, operating a fume extraction system at a single flow rate setting does not take into account the unique characteristics of each weld or weld joint. For example, operating at a single flow rate setting can be suitable for certain types of configurations (e.g., welds performed in a wider work envelope), but yet inadequate in other situations (e.g., welds performed in small, confined spaces).
Fume extraction is also a balance of removing welding fumes while maintaining adequate shielding gas coverage (e.g., the inert or semi-inert gas environment that is necessary to protect molten weld metal from oxygen, nitrogen, or hydrogen in the air). For example, a fume extraction flow rate setting that is otherwise suitable for a wide-open weld joint may compromise shielding gas coverage for a weld joint that is situated in a small or confined space, respectively, based on the extraction of shielding gas surrounding the molten weld metal. Consequently, many operators set a fume extraction flow rate at a bottom end of a range to maintain shielding gas coverage for a majority of the welds, irrespective of an ideal fume extraction flow rate for a particular weld or configuration.
In view of the foregoing problems and shortcomings of existing fume extraction systems, the present application describes a system and method to overcome these shortcomings.
According to an exemplary embodiment, a method of controlling fume extraction comprises utilizing a welding sequence associated with at least two welds, wherein the welding sequence defines at least a first welding procedure to create a first weld including a first weld parameter and a second welding procedure to create a second weld including a second weld parameter; wherein the first welding procedure includes a first flow rate based on the first weld parameter, and wherein the second welding procedure includes a second flow rate based on the second weld parameter; and wherein the method further comprises setting a flow control device associated with fume extraction to the first flow rate during the first weld of the welding sequence, and setting the flow control device to the second flow rate during the second weld of the welding sequence.
The descriptions of the invention do not limit the words used in the claims in any way or the scope of the claims or invention. The words used in the claims have all of their full ordinary meanings
In the accompanying drawings, which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to exemplify embodiments of this invention. It will be appreciated that illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one embodiment of boundaries. In some embodiments, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some embodiments, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.
The following includes definitions of exemplary terms used throughout the disclosure. Both singular and plural forms of all terms fall within each meaning:
“Component,” as used herein can be defined as a portion of hardware, a portion of software, or a combination thereof. A portion of hardware can include at least a processor and a portion of memory, wherein the memory includes an instruction to execute.
“Logic,” synonymous with “circuit” as used herein, includes but is not limited to hardware, firmware, software and/or combinations of each to perform a function(s) or an action(s). For example, based on a desired application or needs, logic may include a software controlled microprocessor, discrete logic such as an application specific integrated circuit (ASIC), or other programmed logic device and/or controller. Logic may also be fully embodied as software.
“Software”, as used herein, includes but is not limited to one or more computer readable and/or executable instructions that cause a computer, logic, or other electronic device to perform functions, actions, and/or behave in a desired manner. The instructions may be embodied in various forms such as routines, algorithms, modules or programs including separate applications or code from dynamically linked libraries. Software may also be implemented in various forms such as a stand-alone program, a function call, a servlet, an applet, instructions stored in a memory, part of an operating system or other type of executable instructions. It will be appreciated by one of ordinary skill in the art that the form of software is dependent on, for example, requirements of a desired application, the environment it runs on, and/or the desires of a designer/programmer or the like.
Embodiments of systems, architectures, processes, and methods for controlling fume extraction are disclosed herein. The examples and figures herein are illustrative only and are not meant to limit the subject invention, which is measured by the scope and spirit of the claims. The showings are for the purpose of illustrating exemplary embodiments of the subject invention only and not for the purpose of limiting same.
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Furthermore, the controller 102 can directly or indirectly control one or more fume extraction systems, flow control devices, welding power sources, parameters, robots, fixtures, feeders, etc. associated with one or more welding sequences or processes, for example, stored in the memory 108. An example of direct control is the setting of a fume extraction flow rate associated with a fume extraction system, the setting of a flow control device, or the setting of various welding parameters (voltage, current, waveform, etc.) associated with a welding power supply. An example of indirect control is the communication of welding position, path, speed, etc. to a separate controller or other peripheral device. The controller 102 may also execute welding sequences, for example, as described in US Pub. No. 2014/0042136 (Ser. No. 13/803,032), which is hereby incorporated by reference in its entirety. The hierarchy of the various controllers that may be associated with a welding cell can be arranged in any suitable manner to communicate the appropriate commands to the desired devices. It is appreciated, that as used herein, the welding sequence 106 may be used as a welding routine.
Moreover, those skilled in the art will appreciate that the inventive methods may be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which may be operatively coupled to one or more associated devices. The illustrated aspects of the invention may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices. For instance, a remote database, a local database, a cloud-computing platform, a cloud database, or a combination thereof can be utilized with the controller 102.
The controller 102 can utilize various computing environments for implementing aspects of the invention, including, for example, a computer, wherein the computer includes a processing unit, a system memory, and a system bus. The system bus couples system components including, but not limited to the system memory to the processing unit. The processing unit may be any of various commercially available processors. Dual microprocessors and other multi-processor architectures also can be employed as the processing unit. The system bus can be any of several types of bus structure including a memory bus or memory controller, a peripheral bus and a local bus using any of a variety of commercially available bus architectures. The system memory can include read only memory (ROM) and random access memory (RAM).
The controller 102 can include at least some form of computer readable media. Computer readable media can be any available media that can be accessed by the computer. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the controller 102. A number of program modules may be stored in the drives and RAM, including an operating system, one or more application programs, other program modules, and program data.
The controller 102 can operate in a networked environment using logical and/or physical connections to one or more remote computers. The remote computer(s) can be a workstation, a server computer, a router, a personal computer, microprocessor based entertainment appliance, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer. The logical connections depicted include a local area network (LAN) and a wide area network (WAN). Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
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In one embodiment, each welding procedure may comprise one or more weld parameters associated with creating each of the welds including, but not limited to, a cycle time, a duty cycle, a welding process type (e.g., gas metal arc welding—GMAW; gas tungsten arc welding—GTAW; flux-cored arc welding—FCAW; shielded metal arc welding—SMAW, etc.), a welding wire type, a wire size (e.g., diameter), a wire feed speed, a waveform, an amperage, a voltage, a trim value, a polarity (direct current electrode positive—DCEP; direct current electrode negative—DCEN), a deposition rate, a transfer mode (e.g., short circuit, globular transfer, spray transfer, pulse-spray transfer, etc.) a welding joint configuration (e.g., a corner weld, a butt weld, etc.), a type of base material, a welding power source setting, a wire feeder setting, a welding gun setting, a remote amperage control setting, a remote voltage control setting, a shielding gas flow rate, and a shielding gas composition (e.g., 100% CO2, Argon/CO2 blend, etc.).
In some embodiments, each welding procedure may also include a flow rate corresponding to the one or more welds associated with the welding procedure. For example, in such embodiments, the flow rate may be based on the one or more weld parameters related to performing a particular weld. In this manner, each welding sequence 106 may include flow rates that are defined relative to one or more weld parameters so that each flow rate is tailored to each weld in the welding sequence 106. For instance, for a welding sequence 106 comprising two welds, the controller 102 may utilize the welding sequence 106 to set the flow control device 200 to a first flow rate during the first weld of the welding sequence, and set the flow control device 200 to a second flow rate during the second weld of the welding sequence. In this embodiment, the welding sequence 106 may comprise a first welding procedure that includes a first weld parameter and a second welding procedure that includes a second weld parameter. In such embodiments, the first welding procedure may also include the first flow rate based on the first weld parameter and the second welding procedure may also include the second flow rate based on the second weld parameter. In this manner, each fume extraction flow rate may be defined with respect to the unique attributes or characteristics (e.g., one or more weld parameters) associated with creating each weld.
In some embodiments, the flow rates associated with the welding procedures and welds may comprise nominal flow rates or settings, such that actual or target flow rates may be determined “on-the-fly” (e.g., in real time or near real time) during welding based on operator selections/settings and/or various types of feedback (e.g., via sensors 122 of
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In certain embodiments, the welding sequence 106 may also reside in a remote memory storage device and/or external storage media 110. For example, in some embodiments, the external storage media 110 may also be associated with a particular assembly (e.g., serial number, model number, etc.). In this manner, the controller 102 could execute instructions in accordance with a welding sequence 106 that resides in the external storage media 110 for setting the flow control device 200 to a desired flow rate for each weld in the welding sequence 106.
As discussed above, the external storage media 110 may include, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other magnetic storage devices, or any other medium that can be accessed by controller 102. However, in certain embodiments, the external storage media 110 may comprise a data store that resides in a remote location or server (e.g., on the cloud) for enabling a weld operator to access a welding sequence 106 associated with a welded assembly via a wide area network, such as the Internet.
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In another embodiment, the controller 102 may determine a flow rate based on the one or more weld parameters associated with a welding procedure. For example, the controller 102 may utilize a welding sequence 106 that defines at least a first welding procedure to create a first weld and a second welding procedure to create a second weld, respectively, for determining a first flow rate for the first weld and a second flow rate for the second weld. In this embodiment, the first flow rate may be determined based on a first weld parameter associated with the first welding procedure, and the second flow rate may be determined based on a second weld parameter associated with the second welding procedure. In this manner, the controller 102 may comprise logic to interpret one or more weld parameters associated with a welding procedure to determine a flow rate corresponding to each weld and/or welding procedure. Yet, as discussed above, in other embodiments, the controller 102 may also be configured to adjust the setting of the flow control device 200 (e.g., fan speed, valve setting, damper position, and the like) to attain the desired flow rate.
In further embodiments, the controller 102 may execute one or more computer implementable instructions (e.g., an algorithm) to determine a flow rate based on the one or more weld parameters associated with a particular welding procedure, including, for example, variable/selectable inputs, and in some embodiments, feedback during welding (including, e.g., from sensors, a weld score, etc.). (The weld score or weld scoring feature can include the techniques described in U.S. Pat. No. 8,884,177, which is incorporated herein by reference in its entirety.) For example, if the system monitors a drop in the weld score feedback, it can reduce the fume extraction flow. In another example, if a welding procedure associated with a weld defines a certain voltage (e.g., 24V for a GMAW spray transfer process), and the weld that is being performed is an in-corner weld (e.g., a weld configuration comprising an intersection of three planes), the controller 102 may comprise logic to interpret the input corresponding to the voltage value (24 V) and the weld configuration (in-corner weld) to determine a flow rate that corresponds with the weld parameters (e.g., the voltage and particular configuration). In this respect, it should be appreciated that a variety of weld parameters may be utilized by the controller 102 to determine the flow rate, such as, for example, any type of weld parameter described in the present application (as described above).
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Yet, in other embodiments, the operator's selection may comprise work data associated with an assembly. For instance, work data may comprise identifying information (e.g., a part number, a serial number, a model number, and the like) associated with the assembly. In such embodiments, the controller 102 may analyze the work data (e.g., via a query) to retrieve a welding sequence 106 associated with the work data from the system's memory 108 and/or external storage media 110. For example, the controller 102 may associate the work data with a specific welding sequence 106 that is routinely utilized for producing the assembly, such as, for example, when a manufacturer or fabricator produces multiple units of the assembly to meet reoccurring customer demand.
In some embodiments, the controller 102 may be operatively connected to a remote user interface 112 such as, for example, a laptop, a desktop, a smart phone, a tablet, or other computer device that is connected to the controller 102 via a wireless network (e.g., LAN or WAN) or physical connection. In some embodiments, the controller 102 can be configured to determine a flow rate via a lookup table (e.g., residing in the memory 108 and/or in the external storage media 110) that includes suggested flow rate values corresponding to the one or more selections made via the user interface 112. For example, an operator's selection of a certain welding process type (e.g., FCAW) could prompt the controller 102 to select a suggested flow rate setting that is higher than the suggested flow rate setting associated with another type of welding process (e.g., TIG). As another example, an operator's selection of a different setting (e.g., an increased voltage value) could result in a higher flow rate setting versus an original setting (e.g., a lower voltage value). In some embodiments, an operator may send a welding sequence 106 to the controller 102 via the user interface (e.g., 112 in
In the illustrated embodiment, the exemplary welding work cell 301 is configured to perform a GMAW process (i.e., MIG welding) with a welding gun 306, a power source 302, and a wire feeder 304. However, it should be appreciated that other types of welding configurations are also contemplated (e.g., a power source and an electrode holder or a welding torch). In this manner, the welding work cell 301 could be configured to perform a variety of welding processes, such as, for example, shielding metal arc welding SMAW, FCAW, pulsed MIG, TIG, and the like. In some exemplary embodiments, the welding gun 306 may comprise a welding fume gun (e.g., 408 in
It is also to be appreciated that the welding work cell 301 may comprise various system arrangements, including automatic, semi-automatic, on-site, and/or manual welding systems with similar components. Moreover, a person of skill in the art should understand that fume extraction control system of the present application may also be adapted to extract fumes and particulate produced by other fabrication processes, including, but not limited to, thermal cutting (e.g., oxy-fuel cutting), plasma cutting, laser-cutting, and the like.
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In such embodiments, the fume extraction system 400 may include a motor 406 that is configured to actuate a motorized fan (not shown) that generates a negative pressure/draft (i.e., fume extraction flow) through the arm 404 and through a vacuum filter (not shown) for withdrawing welding fumes and particulate generated in the vicinity of the arm 404. As discussed above, the controller 102 may send signals to the motor 406 (e.g., a variable frequency drive) to regulate the motor 406 fan speed in accordance with the desired flow rate (e.g., a first flow rate during a first weld of the welding sequence, a second flow rate during a second weld of the welding sequence, etc.).
In some embodiments, the flow control device 200 may comprise a welding fume gun 408 that is operatively connected to the controller 102 and to the fume extraction unit 402. As discussed above, the welding fume gun 408 may be configured to perform welds and withdraw welding fumes through a fume extraction chamber and/or hose (not shown) disposed in the welding fume gun 408. In such embodiments, the fume extraction chamber/and or hose can be operatively connected to the fume extraction unit 402 such that the fume extraction unit 402 produces a negative draft/pressure through the chamber and/or hose, respectively. In some embodiments, the welding fume gun 408 may also be retrofitted to include a flow control device 200. For example, in some embodiments, the welding fume gun 408 may include a flow control device 200 comprising an actuated valve or damper (not shown) that is configured to vary the size of the flow opening in response to signals sent by the controller 102 to the welding fume gun 408. In this manner, the controller 102 may set the flow control device 200 associated with the welding fume gun 408 to a fume extraction flow rate setting (e.g., valve setting or damper position, etc.) in accordance with the flow rate designated for the weld in the welding sequence. In some embodiments, the flow control device 200 may comprise other exemplary components (e.g., a VFD fan, a control valve, a smart valve, a positioner, an actuator for modulating a valve or a damper, etc.) of the welding fume gun 408 or the fume extraction unit 402. In some embodiments, the flow control device 200 may comprise a retrofittable component (e.g., a actuator, a VFD fan, etc.) of the welding fume gun 408 or the fume extraction unit 402, respectively, so that the welding fume gun 408 or the extraction unit 402 are capable of regulating the flow rate in response to signals sent by the controller 102. However, it is also contemplated that in certain embodiments, the flow control device 200 may comprise a downdraft table, an extraction hood, a weld booth, an air purifying respirator, and the like.
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According to one embodiment, the controller 102 may comprise logic to determine a flow rate based on the weld data that is transmitted to the controller 102 by the one or more sensors 122. For example, a sensor 122 may be connected to the power source 302 for monitoring voltage during a weld such that the controller 102 may determine a flow rate in accordance with the recorded voltage value. In such embodiments, the controller 102 may then send a signal to the flow control device 200 to set the flow control device 200 to the determined flow rate, thereby exemplifying a closed loop control system. In some embodiments, as discussed above, feedback from a sensor 122 may be used to adjust a nominal flow rate specified in the welding sequence 106. In another embodiment, the controller 102 may comprise logic to determine a flow rate based on other weld data associated with the welding system 300, such as, for example, the measured shielding gas flow rate and/or shielding gas composition, respectively. In yet another embodiment, the controller 102 may monitor the welding wire type 310 (e.g., machine and/or wire feeder setting) that is being used to perform a weld to determine a flow rate based on the type of welding wire (e.g., stainless steel, mild steel, aluminum, etc.). However, it should also be appreciated that the controller 102 may monitor the type of base material that is being welded (e.g., based on a machine and/or user interface setting) to determine a flow rate with respect to the base material. Additionally, in some embodiments, the controller 102 may disable and lock the welding power source 302 if the controller 102 does not detect a signal from the flow control device 200, such as, for example, if the flow control device 200 is turned off or inoperative due to maintenance such as, for example, a filter replacement. Yet, in further embodiments, the controller 102 may comprise logic to decrease the flow rate when the welding power source 302 is inactive for energy conservation purposes. In this manner, it should be understood that a wide variety of arrangements for monitoring and transmitting weld data during a weld are contemplated for controlling the flow control device 200 or the welding power source 302.
In some embodiments, the controller 102 may be operatively connected to an air check component 120 that is configured to monitor the fume data generated during the welding process. In certain embodiments, the air check component 120 may comprise a sensor that monitors the fume data to detect the level of airborne contaminants in the air. In this manner, the air check component 120 may include an analyzer having a probe for monitoring the level of airborne contaminants. In some embodiments, the controller 102 may assess the fume data relative to permissible exposure limits set forth by a government agency. In some embodiments, the controller 102 may create a notification if the fume data has surpassed a predetermined threshold value. In other embodiments, the controller 102 may be configured to create and send the notification to a welder or weld operator. For example, the controller 102 may be operatively connected to a welder's helmet (not shown) and configured to provide the welder an audio alarm and/or a visual notification if the fume data has surpassed a predetermined threshold value. In this way, it is also contemplated that a welding helmet may be configured to operate with the controller 102 for providing a welder a real time indication of the air quality in the welding system 300. In another embodiment, it is also contemplated that the controller 102 may send a signal to the welder's helmet to notify the welder that it is time to replace the filter (e.g., filter end of life), or if there is an insufficient flow rate relative to the fume data. In other embodiments, the controller 102 may increase the flow rate in response to an indication that the fume data has surpassed a predetermined threshold value.
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However, it should be understood that in alternative embodiments, the method may also include utilizing one or more sensors for monitoring a welding system for receiving weld data during a weld to determine a flow rate based on the weld data. For example, the weld data may comprise any form of weld data and/or feedback described in the present application. In certain embodiments, the weld data may also comprise any form of a weld parameter described herein. For example, and referring to
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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 may be 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 of 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.
While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in some detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.