Voltage sensing wire feeder with weld procedure memories

• US 10,076,809 B2
• Filed: 03/13/2013
• Issued: 09/18/2018
• Est. Priority Date: 03/13/2013
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Rappl, James Francis, Ihde, Jeffrey Ray, Feldhausen, Joseph Edward, Reitmeyer, Timothy Jay, Lahti, Thomas Don, Byron, Clay Alan, Novak, Michael Hilary
• Primary Examiner(s): Tran, Thien S
• Application Number:
  US13/799,367
• Publication Number:
  US 20140263256A1
• Time in Patent Office: 2,015 Days
• CPC Class Codes: B23K 37/0247 Driving means
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: B23K 9/1087 Arc welding using remote control
• CPC Class Codes: B23K 9/124 Circuits or methods for feeding welding wire

Abstract

A voltage sensing wire feeder includes a storage device and a user interface. The user interface is configured to receive a first selection and a second selection. The first selection is configured to direct the voltage sensing wire feeder to use a first group of settings stored in the storage device, and the second selection is configured to direct the voltage sensing wire feeder to use a second group of settings stored in the storage device.

Claims

1. A voltage sensing wire feeder powered by welding power from a welding power supply provided via a weld cable, the voltage sensing wire feeder comprising:

a voltage sensing lead configured to electrically couple the voltage sensing wire feeder to a workpiece connection;

a contactor configured to transmit or prevent the welding power from the voltage sensing wire feeder to a welding torch;

a memory device storing a first weld procedure memory comprising a first group of operational settings and a second weld procedure memory comprising a second group of operational settings;

a user interface configured to receive user desired selection of one of the first weld procedure memory or the second weld procedure memory; and

wire feeder control circuitry configured to;

control operation of the contactor and a wire feed speed of the voltage sensing wire feeder based on the first group of operational settings and to provide the welding power supply with a first voltage output setting when the first weld procedure memory is selected; and

control operation of the contactor and the wire feed speed the voltage sensing wire feeder based on the second group of operational settings and to provide the welding power supply with a second voltage output setting when the second weld procedure memory is selected,

wherein the operational settings provided to the welding power supply are provided as a data signal over the welding power on a same electrical conductor of the weld cable.

2. The voltage sensing wire feeder of claim 1, wherein the voltage sensing wire feeder and the welding power supply are configured to communicate with one another over the weld cable via weld cable communication (WCC).

3. The voltage sensing wire feeder of claim 1, wherein the wire feeder control circuitry is configured to receive combined welding power and data from the welding power supply, and to provide combined welding power and data to the welding power supply, wherein the combined welding power and data enables communication between the voltage sensing wire feeder and the welding power supply for using the first group of operational settings, the second group of operational settings, or any combination thereof.

4. The voltage sensing wire feeder of claim 1, wherein the user interface comprises an input device configured to receive the user desired selection of the first weld procedure memory or the second weld procedure memory.

5. The voltage sensing wire feeder of claim 1, wherein the first group of operational settings or the second group of operational settings comprises a power supply voltage setting, a power supply current setting, a power supply type setting, a power supply configuration setting, a system configuration setting, an arc control setting, a welding process setting, a welding sequence, or any combination thereof.

6. The voltage sensing wire feeder of claim 1, wherein the first weld procedure memory or the second weld procedure memory comprises data corresponding to a process, a sequence, or any combination thereof that enables the welding power supply and the voltage sensing wire feeder to work together.

7. The voltage sensing wire feeder of claim 6, wherein the data corresponding to the process, the sequence, or any combination thereof comprises a voltage setting, a current setting, a wire speed, a time, or any combination thereof.

8. The voltage sensing wire feeder of claim 6, wherein the first weld procedure memory or the second weld procedure memory comprises data corresponding to a process, wherein the process comprises flux-cored arc welding (FCAW) no shielding gas, metal inert gas (MIG) with shielding gas, FCA W with shielding gas, pulsed MIG, stick 6010, stick 7108, lift arc tungsten inert gas (TIG), scratch start TIG, air carbon arc gouging (ACAG), remote lift arc TIG, or any combination thereof.

9. The voltage sensing wire feeder of claim 1, wherein the voltage sensing wire feeder is coupled to the welding power supply by the weld cable and a voltage sense cable, wherein the voltage sense cable is the voltage sensing lead.

21. The voltage sensing wire feeder of claim 1, wherein the workpiece connection forms an electrical circuit between the welding power supply through the welding cable, the voltage sensing lead between the wire feeder and a workpiece, and a work cable from the workpiece to the welding power supply.

10. A voltage sensing wire feeder powered by welding power from a welding power supply, the voltage sensing wire feeder comprising:

a voltage sensing lead configured to electrically couple the voltage sensing wire feeder to the welding power supply via a workpiece connection;

a contactor configured to transmit or prevent the welding power from the voltage sensing wire feeder to a welding torch;

a memory device storing a plurality of weld procedure memories each comprising operational settings;

a user interface configured to receive a user selection of a desired one of the weld procedure memories; and

wire feeder control circuitry powered by weld power received over a weld cable, the wire feeder control circuitry being configured to;

control operation of the contactor and a wire feed speed of the voltage sensing wire feeder based on the operational settings of the desired weld procedure memory; and

provide the welding power supply with at least one operational setting for the desired weld procedure memory,

wherein the operational setting provided to the welding power supply is provided as a data signal over the welding power on a same electrical conductor of the weld cable.

11. The voltage sensing wire feeder of claim 10, wherein the wire feeder is configured to communicate, via weld cable communication (WCC), data related to control of a welding application based on one of the weld procedure memories.

12. The voltage sensing wire feeder of claim 10, wherein the wire feeder is electrically coupled to the welding power supply by the weld cable and a voltage sense cable, wherein the voltage sense cable is the voltage sensing lead.

13. The voltage sensing wire feeder of claim 10, wherein the wire feeder comprises a first connector configured to couple to a voltage sense cable and a second connector configured to couple to a welding torch trigger connector.

14. The wire feeder of claim 10, wherein the voltage sensing wire feeder provides the welding power supply with a power supply voltage setting, a power supply current setting, a power supply type setting, a power supply configuration setting, a system configuration setting, an arc control setting, a welding process setting, a welding sequence, or any combination thereof as the operational setting provided to the welding power supply.

15. A voltage sensing wire feeder powered by welding power from a welding power supply provided via a weld cable, the voltage sensing wire feeder comprising:

a voltage sensing connector configured to couple to a voltage sensing lead that electrically couples the voltage sensing wire feeder to the welding power supply via a workpiece connection;

a contactor configured to transmit or prevent the welding power from the voltage sensing wire feeder to a welding torch;

a memory device storing a first weld procedure memory comprising a first plurality of operational settings and a second weld procedure memory comprising a second plurality of operational settings;

a user interface configured to receive a user desired selection of one of the first weld procedure memory or the second weld procedure memory, wherein the first weld procedure memory is selected via a selector actuated a first quantity of times and the second weld procedure memory is selected via the selector actuated a second quantity of times; and

wire feeder control circuitry configured to;

control operation of the contactor and a wire feed speed of the voltage sensing wire feeder based on the first plurality of operational settings and to provide the welding power supply with a first voltage output setting when the first weld procedure memory is selected; and

control operation of the contactor and the wire feed speed the voltage sensing wire feeder based on the second plurality of operational settings and to provide the welding power supply with a second voltage output setting when the second weld procedure memory is selected,

wherein the operational settings provided to the welding power supply are provided as a data signal over the welding power on a same electrical conductor of the weld cable.

16. The voltage sensing wire feeder of claim 15, wherein the voltage sensing wire feeder comprises a first connector configured to couple to a voltage sense cable and a second connector configured to couple to a welding torch trigger connector.

17. The voltage sensing wire feeder of claim 15, wherein the user interface enables selection of the first weld procedure memory and the second weld procedure memory by actuating the selector until a desired weld procedure memory is selected.

18. The voltage sensing wire feeder of claim 15, wherein the first weld procedure memory or the second weld procedure memory comprises a power supply voltage setting, a power supply current setting, a power supply type setting, a power supply configuration setting, a system configuration setting, an arc control setting, a welding process setting, a welding sequence, or any combination thereof.

19. The voltage sensing wire feeder of claim 15, wherein the user interface comprises a second selector to select a welding process, a third selector to select a trigger hold option, and a fourth selector to select a gas purge selection.

20. A voltage sensing wire feeder powered by welding power from a welding power supply provided via a first weld cable between the voltage sensing wire feeder and the welding power supply, and the voltage sensing wire feeder comprising:

a voltage sensing connector configured to couple to a voltage sensing lead that electrically couples the voltage sensing wire feeder to the welding power supply via a workpiece connection;

a contactor configured to transmit or prevent the welding power from the voltage sensing wire feeder to a welding torch;

a welding torch connector configured to couple to a second welding cable of a welding torch;

a memory device storing a first weld procedure memory comprising a first plurality of operational settings and a second weld procedure memory comprising a second plurality of operational settings;

a user interface configured to receive a user desired selection of one of the first weld procedure memory or the second weld procedure memory, wherein the first weld procedure memory is selected via a selector actuated a first quantity of times and the second weld procedure memory is selected via the selector actuated a second quantity of times; and

voltage sensing wire feeder control circuitry configured to

control operation of the contactor and a wire feed speed of the voltage sensing wire feeder based on the first plurality of operational settings and to provide the welding power supply with a first voltage output setting when the first weld procedure memory is selected; and

control operation of the contactor and the wire feed speed of the wire feeder based on the second plurality of operational settings and to provide the welding power supply with a second voltage output setting when the second weld procedure memory is selected, and

wherein the operational settings provided to the welding power supply are provided as a data signal via a wireless transceiver of the wire feeder.