Sensor-based power controls for a welding system

• US 10,239,147 B2
• Filed: 10/16/2014
• Issued: 03/26/2019
• Est. Priority Date: 10/16/2014
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Denis, Marc Lee, Hsu, Christopher
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Maye, Ayub
• Application Number:
  US14/516,281
• Publication Number:
  US 20160107257A1
• Time in Patent Office: 1,622 Days
• Field of Search: 219132, 2191377, 2191301, 21913001, 219136
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/1006 Power supply
• CPC Class Codes: B23K 9/1087 Arc welding using remote control

Abstract

A welding system includes a torch motion sensing system associated with a welding torch and is configured to sense welding torch orientations or movements. The welding system also includes a processing system that is configured to vary operation of a power source based on the sensed orientations or movements.

Claims

1. A welding-type system, comprising:

a power source;

a motion sensing system associated with a welding-type tool or accessory and configured to sense an orientation or movement of the welding-type tool or accessory; and

a processing system communicatively coupled to the motion sensing system and configured to;

determine a change in the orientation or movement of the welding-type tool or accessory prior to a power demand from the welding-type tool or accessory;

determine a type of the welding-type tool or accessory associated with the motion sensing system;

based on the type of the welding-type tool or accessory, select a power level sufficient to perform a welding-type operation using the welding-type tool or accessory;

send an indication to energize the power source to provide power at the selected power level, the selected power level being sufficient to operate a welding-type process of the power source or operator tools connected to the power source;

determine that the welding-type tool or accessory has not moved for a duration of time;

determine whether the duration of time exceeds a first threshold or a second threshold;

when the duration of time exceeds a first threshold, place the power source in a first power state; and

when the duration of time exceeds a second threshold, place the power source in a second power state, wherein the first and second power states are altered power generation states from an initial power state.

2. The welding-type system of claim 1, wherein placing the power source in the first power state comprises sending an indication to the power source to reduce power generation to a low-power level that is lower than the ready level when the welding-type tool or accessory has not moved for the duration of time.

3. The welding-type system of claim 1, wherein first power state comprises an idling engine state and the second power state comprises an engine off state.

4. The welding-type system of claim 1, comprising a transceiver configured to transmit information indicative of the determined change in the orientation or movement of the welding-type tool or accessory to the power source.

5. The welding-type system of claim 1, wherein the motion sensing system comprises at least one accelerometer.

6. The welding-type system of claim 1, wherein the motion sensing system is configured to determine one or more predefined gestures, and the processing system is configured to change a corresponding weld process parameter by progressing through a plurality of welding-type process states based at least in part on the determined one or more predefined gestures.

7. The welding-type system of claim 1, comprising a feedback unit configured to provide an alert that the power source is ready to deliver power at one or more power levels.

8. The welding-type system of claim 1, comprising an energy harvester configured to provide power for operation of the motion sensing system or the processing system.

9. The welding-type system of claim 1, wherein placing the power source in the first power state comprises placing the power source in the first power state from an operating state.

10. The welding-type system of claim 1, wherein the processing system is configured to determine a type of the welding-type tool or accessory associated with the motion sensing system based on a tool tag associated with the motion sensing system.

11. The welding-type system of claim 3, wherein the power source comprises a combustion engine.

12. The welding-type system of claim 5, wherein the motion sensing system comprises at least one angular rate sensor configured to measure angular changes of the welding-type tool or accessory.

13. The welding-type system of claim 7, wherein the alert comprises haptic, visual, or audio feedback.

14. A retro-fit kit configured to couple to a welding-type tool or accessory, comprising:

a motion sensing system configured to determine orientation of the welding-type tool or accessory;

a processor communicatively coupled to the motion sensing system and configured to;

determine a type of the welding-type tool or accessory associated with the motion sensing system;

based on the type of the welding-type tool or accessory, select a power level sufficient to perform a welding-type operation using the welding-type tool or accessory;

send the indication to energize the power source to provide power at the ready level by sending the indication to energize the power source at the selected power level; and

send instructions to a power supply for the welding-type tool or accessory to;

provide power in response to movement of the welding-type tool or accessory or in response to a change in orientation of the welding-type tool or accessory, wherein the instructions comprise instructions to reduce power from the power supply when the motion sensing system determines that the determined orientation corresponds to a predefined orientation of the welding-type tool or accessory.

15. The retro-fit kit of claim 14, wherein the processor is configured to send instructions to the power supply to reduce power production when no movement or change in orientation has been detected for a predetermined duration of time.

16. The retro-fit kit of claim 14, wherein the predefined orientation corresponds to an orientation indicative of idleness of the welding-type tool or accessory.

17. The retro-fit kit of claim 14, wherein the predefined orientation comprises the welding-type tool or accessory laying on its side, being upside down, or laying with a working end facing downward.