METHOD AND APPARATUS FOR AUTODETECTION OF CONSUMABLES

• US 20050061784A1
• Filed: 09/18/2003
• Published: 03/24/2005
• Est. Priority Date: 09/18/2003
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Matus, Tim A.
• Granted Patent: US 7,186,944 B2
• Time in Patent Office: Days
• US Class Current: 219/121.540
• CPC Class Codes: B23K 10/006 Control circuits therefor circuits for plasma torches H05H1/36
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: H05H 1/3494 Means for controlling discharge parameters
• CPC Class Codes: H05H 1/36 Circuit arrangements H05H1/38, H05H1/40 take precedence

Abstract

A method and apparatus for automatically determining a consumable type when a consumable is disposed within an electrode holder of a welding-type system is disclosed. The invention includes a detector assembly that measures a physical characteristic of a connected consumable and provides feedback regarding that which is measured. From the feedback, the operating parameters of a welding-type process may be automatically prescribed.

Claims

1. A method of defining a welding-type process, the method comprising:

detecting consumable presence in an electrode holder;

receiving feedback of sensed characteristics of the consumable; and

automatically setting an operating parameter of a welding-type process based on at least consumable type.

2. The method of claim 1 further comprising measuring a resistance between the consumable and the electrode holder, comparing a value of the resistance to a look-up table, and determining consumable type therefrom.

3. The method of claim 1 further comprising measuring a surface light reflectivity of the consumable, comparing a value of surface light reflectivity to a look-up table, and determining consumable type therefrom.

4. The method of claim 1 further comprising measuring a magnetic field induced current in a detector coil, comparing a value of the current to a look-up table, and determining consumable type therefrom.

5. The method of claim 1 further comprising measuring surface sound reflectivity of the consumable, comparing a value of surface sound reflectivity to a looktable, and determining consumable type therefrom.

6. The method of claim 1 wherein the welding-type process includes plasma cutting and the consumable includes a cutting or a gouging component.

7. The method of claim 1 wherein the operating parameter includes at least one of power source output current and gas pressure.

8. The method of claim 1 further comprising displaying an indicator of consumable type on a power source display.

9. A welding-type system comprising:

a power source;

a consumable electrode holder; and

a controller configured to automatically determine a type of consumable disposed in the consumable electrode holder.

10. The system of claim 9 wherein the power source includes a menu window and the controller is further configured to display an indication of consumable type on the menu window.

11. The system of claim 9 wherein the controller is further configured to automatically adjust one or more operating parameters of the power source based on at least consumable type.

12. The system of claim 11 wherein the one or more operating parameters includes at least an amperage of an output current of the power source.

13. The system of claim 9 further comprising a consumable type detector circuit configured to transmit feed-back to the controller indicative of physical characteristics of a consumable disposed in the consumable electrode holder.

14. The system of claim 13 wherein the detector circuit includes a sensor designed to measure a light reflectivity of an outer surface of the consumable.

15. The system of claim 13 wherein the detector circuit includes a sensor designed to measure a resistance of a pin of the consumable connecting the consumable to the consumable electrode holder.

16. The system of claim 13 wherein the detector circuit includes an induction circuit designed to output a current proportional to a magnetic field generated by the consumable.

17. The system of claim 13 wherein the detector circuit includes a sensor designed to measure sound reflectivity of the consumable.

18. A plasma cutter comprising:

a power source configured to condition raw power into a form usable by a plasma cutting process;

a pressurized gas source;

a torch connected to the power source and the pressurized gas source, and configured to effectuate the plasma cutting process; and

means for detecting a type of consumable disposed within the torch.

19. The plasma cutter of claim 18 further comprising means for automatically controlling the power source based on at least the type of consumable.

20. The plasma cutter of claim 19 wherein the type of consumable includes a one-piece consumable.