Patent Application
20170266747
Devices, systems, and methods consistent with embodiments of the present invention relate to engine drive power supplies, and more specifically, methods and systems to control engine drive power supplies with remote control technology.
The use of engine drive welding power supplies has increased due to the increased needs for welding in remote areas. As is generally known, engine drive power supplies use a fuel powered engine to power a generator, which generates electrical input power. This electrical power is turned into welding output power and, in many cases, auxiliary power to power tools, etc. Because engine drive power supplies are typically quite large, they are often positioned at a significant distance from the location of the welding and/or are located remote from the welding making access to the power supply inconvenient and difficult. For example, an engine drive welder can be located outside on the ground while the welder is performing a weld inside a large pipe or tank. This makes control of the power supply very difficult, and can often require two persons in communication to control/change settings on the power supply. This can result in an engine drive welder running longer than needed. Thus, a system and method of control is needed to optimize use and control of engine drive welders in remote conditions.
Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such approaches with embodiments of the present invention as set forth in the remainder of the present application with reference to the drawings.
An exemplary embodiment of the present invention is an engine drive power supply which can be controlled remotely by a user. The remote control device allows the user to control the operation of the engine and/or the welding output of the power supply remotely.
In one embodiment, a welding or cutting system includes a remote control device and a power supply. The remote control device includes at least one user input configured to select a welding or cutting mode of the welding or cutting system and a transmitter configured to wirelessly transmit first transmitted signals representing the welding or cutting mode once the welding or cutting mode is selected via the user input. A welding mode of the welding or cutting mode may be one of a stick welding mode, a gas tungsten arc welding mode (GTAW or TIG), a constant voltage gas metal arc welding mode (GMAW), a flux cored arc welding mode (FCAW), a shielded metal arc welding mode (SMAW), a submerged arc welding mode (SAW), or a hardfacing welding mode. The power supply includes power electronics configured to generate welding or cutting output power from electrical input power, an antenna, and a receiver unit configured to wirelessly receive the first transmitted signals via the antenna. The power supply also includes a controller configured to control the welding or cutting mode in response to the first transmitted signals as received. The welding or cutting system may also include a fuel-powered engine/generator configured to generate the electrical input power. The user input may be configured to select at least one of a current, a voltage, or a wire feed speed of the welding or cutting mode. The transmitter may be configured to wirelessly transmit second transmitted signals once at least one of the current, the voltage, or the wire feed speed is selected via the user input. The second transmitted signals represent at least one of the current, the voltage, or the wire feed speed. The receiver unit may be configured to wirelessly receive the second transmitted signals via the antenna, and the controller may be configured to control at least one of the current, the voltage, or the wire feed speed in response to the second transmitted signals as received. The remote control device may be configured to be programmed to limit control to a single power supply. The welding or cutting system may include a cradle mounted to the power supply that is configured to secure the remote control device to the power supply when the remote control device is not being used. The welding or cutting system may include a power charging device mounted to the power supply that is configured to be docked to the power charging device. The power charging device is configured to charge the remote control device when docked to the power charging device. The remote control device may be configured to be secured to an arm of a welder/cutter, a welding gun, or a cutting torch.
In one embodiment, a welding or cutting system includes a remote control device and a power supply. The power supply includes power electronics configured to generate welding or cutting output power from electrical input power and a controller configured to monitor parameters, functions, and settings of the welding or cutting system. The welding or cutting system may include a fuel-powered engine/generator configured to generate the electrical input power. The parameters, functions, and settings may include at least one of a current setting, a voltage setting, an engine/generator setting, an engine/generator status, a current output, a voltage output, or revolutions per minute (RPM) of the engine. The power supply also includes an antenna and a transmitter unit configured to wirelessly transmit first transmitted signals via the antenna. The first transmitted signals represent the parameters, functions, and settings of the welding or cutting system as monitored by the controller. The remote control device includes a receiver unit configured to wirelessly receive the first transmitted signals and a display screen configured to display representations of the parameters, functions, and settings based on the first transmitted signals as received. The remote control device may also include a speaker, a microphone, and an audio transceiver that are configured to support two-way radio communication between a user positioned at the remote control device and another user positioned at the power supply. The power supply may also include a speaker, a microphone, and an audio transceiver that are configured to support two-way radio communication between a user positioned at the remote control device and another user positioned at the power supply. The remote control device may include a controls portion and a repositionable cover configured to protect the controls portion and the display screen of the remote control device from, for example, welding or cutting spatter.
In one embodiment, a remote control device is configured to control a welding or cutting system. The remote control device includes at least one user input configured to select a welding or cutting mode of the welding or cutting system. A welding mode of the welding or cutting mode may be one of a stick welding mode, a gas tungsten arc welding mode (GTAW or TIG), a constant voltage gas metal arc welding mode (GMAW), a flux cored arc welding mode (FCAW), a shielded metal arc welding mode (SMAW), a submerged arc welding mode (SAW), or a hardfacing welding mode. The remote control device also includes a transmitter configured to wirelessly transmit first transmitted signals representing the welding or cutting mode to the welding or cutting system, once the welding or cutting mode is selected via the user input, to control the welding or cutting mode of the welding or cutting system. The remote control device also includes a receiver unit configured to wirelessly receive second transmitted signals transmitted by the welding or cutting system. The second transmitted signals represent parameters, functions, and settings of the welding or cutting system as monitored by the welding or cutting system. The remote control device also includes a display screen configured to display representations of the parameters, functions, and settings based on the second transmitted signals as received. The remote control device may also include a haptic vibration system configured to provide an indication of an issue with the welding or cutting system in response to the second transmitted signals as received. The remote control device may also include an audio output jack configured to couple to headphones to provide an audio warning to a welder or cutter in response to the second transmitted signals as received. The user input may be configured to select at least one of a current, a voltage, or a wire feed speed of the welding or cutting mode. The transmitter may be configured to wirelessly transmit third transmitted signals to the welding or cutting system, once at least one of the current, the voltage, or the wire feed speed is selected via the at least one user input. The third transmitted signals control at least one of the current, the voltage, or the wire feed speed of the welding or cutting mode when received by the welding or cutting system. The remote control device may be configured to be programmed to selectively control multiple power supplies via the user input.
The above and/or other aspects of the invention will be more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings, in which:
Reference will now be made in detail to various and alternative exemplary embodiments and to the accompanying drawings, with like numerals representing substantially identical structural elements. Each example is provided by way of explanation, and not as a limitation. In fact, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the scope or spirit of the disclosure and claims. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure includes modifications and variations as come within the scope of the appended claims and their equivalents.
Exemplary embodiments described herein are particularly applicable for use in connection with engine drive welding power supplies. Because the structure, function, and operation of these types of engine driven system are well known, a detailed discussion of these systems will not be set forth herein. While exemplary embodiments discussed below are primarily directed to welding systems, embodiments can be used for cutting systems. The focus on welding systems is intended to be exemplary.
Turning now to
As also shown, an antenna 220 can be mounted on the system 100 to allow for wireless communication/control as further described herein. In the embodiment shown, the antenna is mounted to housing 230 of the welder 100. However, in other embodiments, the antenna 220 is secured such that when the housing 230 is opened or removed the antenna 220 is not moved or removed from the welder 100. Further, the antenna 220 can be protected or otherwise housed in a shielding structure (which does not interfere with its operation) to protect the antenna from the elements and damage.
As shown in
A separate input device 407 can be used to stop the engine/generator 310. This can help save fuel, perform engine maintenance, and otherwise extend the life of the system 100. In prior systems it is often required to turn off the engine at the user interface of the system 100. Thus, in prior systems the engine is often left running at idle, even when not used for welding. In some exemplary embodiments, the system 100 monitors the auxiliary power draw via the auxiliary power outlets (described above) and if the auxiliary power draw is above some predetermined level the system 100 will not turn off with the activation of the input 407. That is, in some embodiments, if the auxiliary power draw is above a certain level it can indicate that there are auxiliary devices connected which are in operation and, if the engine is shut off, the power to these devices would stop. In such embodiments, the transmitter 400 can provide an indication to the user that an engine stop would also shut off power to these devices, thus giving the user the choice to leave the engine on or continue to shut it off. For example, if a user presses the input 407 once, and the auxiliary power draw is above a predetermined threshold, the input 407 can blink red (or otherwise provide an indication) to indicate that auxiliary power is being used. After signaling that auxiliary power is being used, the user can then leave the engine running, or press the input 407 again (again a time delay can be used) to shut off the engine. This improves the flexibility of control of the system 100 from a remote location. Of course, the display 401 can be used to display any needed information during start up and/or shut down.
The input 409 can be used to control the idle speed of the engine/generator 310. For example, when the input 409 is used, the engine can go to a first idle mode (low idle) and if pressed again, can go to a second idle mode (high idle). Again, the input 409 can use backlighting, or some other methodology to indicate the idle setting. For example, green can indicate high idle while yellow indicates low idle. Also, the display can be used to display this information. Similarly, the input 411 can be used to control the welding mode for the system 100. For example, the input can be used to cycle through the different possible operation modes (e.g., stick, TIG, CV wire, etc.). That is, if the input is depressed once within a period of time (e.g., 1 second) a first mode is selected, if depressed twice a second mode, etc. Of course other methodologies can be used to cycle through settings, and again color illumination (e.g., a different color for each setting) can indicate to the user which mode of operation is selected. The input 411 (or another input) can also be used to change output settings of the system 100, including current and/or voltage. In some embodiments, the user can adjust the output using actual output voltage and/or current values or can adjust based on a percentage of a preset output of the system (e.g. 60%, etc.) The transmitter 400 will allow for a user to select their desired control methodology.
That is, the inputs 413 and 414 can be used to adjust settings up or down as needed. The inputs can also be used to scroll through options that can be displayed on the display 401. For example, in one exemplary embodiment, the user can use the input 411 to indicate that a desired mode change is requested, and then the user uses the inputs 413/414 to scroll through the options. Additionally/alternatively, once the user selects a mode of operation the user can then use the inputs 413/414 to select desired settings for a given operation, including current, voltage, wire feed speed, etc. In some embodiments, the idle speed (for either high or low idle setting) of the engine can be adjusted using the inputs 413/414. Of course, the above described embodiments are intended to be exemplary and any combination of inputs can be used to control the operation of the system remotely and wirelessly. Further, the remote can be used to control/monitor any aspect of the system 100. Of course, the embodiment shown in
In exemplary embodiments, the control knobs 203/204, for example, on the face of the system 100 will be coupled to servos, motors or other types of motion control devices, that will move/rotate the knobs based on control inputs from the transmitter 400. Thus, if a user selects a current level for stick welding via the remote, the input controls on the face of the system 100 will be physically moved/changed to the corresponding settings to ensure the various controls coincide with the operation of the system 100. In such embodiments a visual inspection of the system 100 will allow for one to determine the settings of the system 100 without the need for looking at the settings on the transmitter 400.
In one embodiment, the remote control device 400 includes a receiver unit 425 configured to wirelessly receive transmitted signals from the system 100. The transmitted signals may represent parameters, functions, and settings of the system 100 that are monitored by the system 100, in accordance with one embodiment. Representations of such parameters, functions, and settings of the system 100 may be displayed on display screen 401 based on the transmitted signals as received. The parameters, functions, and settings may include, for example, a current setting, a voltage setting, an engine/generator setting, an engine/generator status, a current output, a voltage output, or revolutions per minute (RPM) of the engine. In one embodiment, the remote control device 400 includes a PC board/controller 430 configured to facilitate implementation of the functions of the remote control device 400 described herein. The receiver unit 425 may be configured to receive signals representing other parameters as well, in accordance with other embodiments.
In a further exemplary embodiment, the transmitter 400 can have a shortwave communication ability. For example, the transmitter 400 can have a speaker 435, a microphone 440, and an audio transmitter/receiver (transceiver) 445 similar to that used in short wave, two-way radio communication to communicate with another user positioned near the system 100. The system 100 can also have a speaker 240, a microphone 250, and an audio transceiver 370 to allow someone positioned near the system 100 to communicate with the welder at the remote control device 400. In accordance with one embodiment, particular elements of the remote control device 400, as described herein, may be integrated into a welding or cutting helmet to provide the functionality described herein.
In one embodiment, the controller 350 of the system 100 is configured to control a welding mode of the system 100 in response to the receiver unit 330 of the system 100 receiving transmitted signals from the remote control device 400 that are presentative of a selected welding mode. In another embodiment, the controller 350 of the system 100 is configured to control a welding current, a welding voltage, or a wire feed speed of the system 100 in response to the receiver unit 330 of the system 100 receiving transmitted signals from the remote control device 400 that are representative of a selected welding current, a selected welding voltage, or a selected wire feed speed.
In one embodiment, the controller 350 of the system 100 is configured to monitor parameters, functions, and settings of the system 100. The transmitter unit 360 of the system 100 is configured to wirelessly transmit signals (that represent the parameters, functions, and settings of the system 100 as monitored) via the antenna 220 to the remote control device 400.
In additional embodiments, the transmitter 400 can be equipment with a magnet on a surface of its housing 403 so that the remote can be magnetically mounted to the system 100, the housing 230, or any ferrous metal surface (e.g., a workpiece.)
In some exemplary embodiments, the transmitter 400 can be equipped with a haptic vibration system 450 (motor, controller, etc.) which provides an indication of an issue with the welding operation. For example, the system 100 can communicate to the transmitter 400 that the fuel level is low, or any other issue with the performance/output of the system 100, and trigger the use of the haptic vibration system 450. When the user senses the vibration of the transmitter 400 the user is aware that there is an issue with the system and can stop welding at an appropriate point to determine the issue—which can be displayed on the display of the remote control device 400.
In some exemplary embodiments, the transmitter 400 can have an audio output jack 460 to which a user can couple headphones so that an audio warning can be provided during welding as needed. For example, an audio warning of “Fuel level low” can be provided to the welder while welding. Of course, any other audio warning or information can be provided as well.
As state previously herein, while exemplary embodiments discussed herein are primarily directed to welding systems, embodiments can be used for cutting systems.
It should be understood that the housing 812 illustrated in
As shown in
While the disclosed subject matter of the present application has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the claimed subject matter. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the described subject matter without departing from its scope. Therefore, it is intended that the described subject matter not be limited to the particular embodiment disclosed, but that the disclosed subject matter will include all embodiments falling within the scope of the present specification.
The present application claims priority to U.S. Provisional Patent Application No. 62/310,070, filed on Mar. 18, 2016, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62310070 | Mar 2016 | US |
