Stick welding electrode holder systems and methods

• US 10,593,230 B2
• Filed: 07/15/2016
• Issued: 03/17/2020
• Est. Priority Date: 08/12/2015
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Becker, William Joshua, Marcusen, David Paul
• Primary Examiner(s): Utama, Robert J
• Application Number:
  US15/211,743
• Publication Number:
  US 20170046975A1
• Time in Patent Office: 1,341 Days
• Field of Search: 434234, 434219
• CPC Class Codes: B23K 9/282 Electrode holders not supplying shielding means to the electrode
• CPC Class Codes: B23K 9/287 Supporting devices for electrode holders not restricted to arc welding B23K37/02
• CPC Class Codes: G09B 19/003 Repetitive work cycles; Sequence of movements
• CPC Class Codes: G09B 19/24 Use of tools
• CPC Class Codes: G09B 9/00 Simulators for teaching or training purposes for the use of weapons F41; computing aspects G06; protocols for games, networked simulations or virtual reality H04L67/131

Abstract

Present embodiments include systems and methods for stick welding applications. In certain embodiments, simulation stick welding electrode holders may include stick electrode retraction assemblies configured to mechanically retract a simulation stick electrode toward the stick electrode retraction assembly to simulate consumption of the simulation stick electrode during a simulated stick welding process. In addition, in certain embodiments, stick welding electrode holders may include various input and output elements that enable, for example, control inputs to be input via the stick welding electrode holders, and operational statuses to be output via the stick welding electrode holders. Furthermore, in certain embodiments, a welding training system interface may be used to facilitate communication and cooperation of various stick welding electrode holders with a welding training system.

Claims

1. A stick electrode holder comprising:

a handle and an outer structure coupled to a distal end of the handle, wherein the outer structure is configured to at least partially surround a stick electrode holding assembly configured to hold a stick electrode; and

one or more input elements configured to receive user inputs relating to a welding system to enable or disable welding power to the stick electrode holder or to enable selection of options relating to operation of the stick electrode holder,

wherein;

the stick electrode holding assembly is configured to orient the stick electrode in a plurality of angular orientations relative to the stick electrode holder,

the stick electrode holding assembly comprises a plurality of discrete slots into which the stick electrode is configured to be inserted, wherein each discrete slot of the plurality of discrete slots has a respective discrete angular orientation, and

the stick electrode holder is in communication with control circuitry configured to accept a user input relating to a selected discrete angular orientation.

2. The stick electrode holder of claim 1, further comprising a welding power indicator configured to indicate whether the welding power to the stick electrode holder has been enabled or disabled.

3. The stick electrode holder of claim 1, wherein:

the stick electrode holder is electrically coupled to a connection box comprising a contactor, and

the stick electrode holder is configured to transmit a signal to enable or disable the welding power to the contactor.

4. The stick electrode holder of claim 1, wherein the one or more input elements comprises one or more buttons.

5. The stick electrode holder of claim 4, wherein the one or more buttons comprise at least one button configured to control navigation through menus displayed on a display of the welding system.

6. The stick electrode holder of claim 1, wherein the stick electrode holding assembly is configured to deliver an electrical current through the stick electrode, wherein the electrical current is sufficient to generate a welding arc to a workpiece through a tip of the stick electrode during an actual stick welding process.

7. The stick electrode holder of claim 1, wherein the one or more input elements are disposed on the handle.

8. The stick electrode holder of claim 1, wherein the one or more input elements are disposed on the outer structure.

9. The stick electrode holder of claim 1, wherein the control circuitry is configured to determine an actual orientation of the stick electrode based at least in part on the user input.

10. The stick electrode holder of claim 1, wherein the stick electrode holder is in communication with control circuitry configured to determine a selected angular orientation based at least in part on feedback from a position detecting system.

11. The stick electrode holder of claim 10, wherein the position detecting system is a position detecting system of a weld training system.

12. The stick electrode holder of claim 1, wherein the stick electrode holding assembly is configured to be rotated with respect to the stick electrode holder to orient the stick electrode in a plurality of continuous angular orientations.

13. The stick electrode holder of claim 1, wherein the stick electrode holding assembly is configured to be fixed into one of a plurality of discrete angular orientations.

14. The stick electrode holder of claim 1, further comprising a sensor configured to detect a selected angular orientation of the stick electrode.

15. The stick electrode holder of claim 14, wherein the sensor is communicatively coupled to a processor.

16. The stick electrode holder of claim 1, further comprising a plurality of sets of light emitting diodes fixedly connected to the outer structure of the stick electrode holding assembly.

17. The stick electrode holder of claim 16, further comprising a position detecting system configured to detect light.

18. The stick electrode holder of claim 16, wherein the plurality of sets of light emitting diodes are fixedly connected to the stick electrode holding assembly.

19. The stick electrode holder of claim 16, wherein each set of light emitting diodes comprises a plurality of light emitting diodes configured to emit light, wherein each of the plurality of light emitting diodes emit light in a substantially parallel direction with respect to all others of the plurality of LEDs in the each set of LEDs.

20. The stick electrode holder of claim 19, wherein each respective set of light emitting diodes shine in a different direction than other sets of light emitting diodes.

21. The stick electrode holder of claim 1, wherein the stick electrode holding assembly comprises a stick electrode retraction assembly configured to mechanically retract a stick electrode toward the stick electrode holding assembly to simulate consumption of the stick electrode during a simulated stick welding process.

22. The stick electrode holder of claim 21, wherein the stick electrode retraction assembly is configured to receive control signals from a processor to control the mechanical retraction.

23. The stick electrode holder of claim 1, further comprising a sleeve configured to fit circumferentially around a distal end of the stick electrode.

24. The stick electrode holder of claim 1, further comprising a trigger that does not control welding power to the stick electrode.

25. The stick electrode holder of claim 1, further comprising a trigger that initiates the stick electrode holding assembly to extend the stick electrode from the stick electrode holding assembly to a first position.