Systems, Methods, and Devices for Transmitting Information to Thermal Processing Systems

• US 20130264317A1
• Filed: 03/15/2013
• Published: 10/10/2013
• Est. Priority Date: 04/04/2012
• Status: Active Grant

• Current Assignee: Hypertherm Incorporated
• Original Assignee: Hypertherm Incorporated
• Inventors: Hoffa, Michael, Shipulski, Michael, Hansen, Brett A.
• Granted Patent: US 10,486,260 B2
• Time in Patent Office: Days
• US Class Current: 219/121.53
• CPC Class Codes: B23K 10/00 Welding or cutting by means of a plasma
• CPC Class Codes: B23K 10/006 Control circuits therefor circuits for plasma torches H05H1/36
• CPC Class Codes: B23K 10/02 Plasma welding
• CPC Class Codes: B23K 26/21 by welding
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 26/702 Auxiliary equipment
• CPC Class Codes: B23K 9/16 making use of shielding gas selection of media B23K35/38
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R
• CPC Class Codes: H05H 1/34 Details, e.g. electrodes, nozzles
• CPC Class Codes: H05H 1/3494 Means for controlling discharge parameters

Abstract

In some aspects, a replaceable consumable component for performing a cutting or welding operation can include a body and a readable data storage device coupled to the body or integrated within the body, wherein the data storage device contains an operation instruction for a cutting or welding device.

Claims

1. A replaceable consumable component for performing a cutting or welding operation, the consumable component comprising:

a body; and

a readable data storage device coupled to the body or integrated within the body, wherein the data storage device contains an operation instruction for a cutting or welding device.

2. The consumable component of claim 1, wherein the operation instruction comprises a cutting program.

3. The consumable component of claim 2, wherein the cutting program comprises torch system setup values.

4. The consumable component of claim 1, wherein the operation instruction comprises a workpiece cutting application.

5. The consumable component of claim 1, wherein the operation instruction comprises a firmware update.

6. The consumable component of claim 1, wherein the replaceable consumable component comprises a component of a thermal processing torch.

7. The consumable component of claim 1, wherein the readable data storage device comprises an RFID tag.

8. The consumable component of claim 1, wherein the readable data storage device is also rewritable.

9. A torch for a cutting or welding process coupled to a controller of a thermal processing system, the torch comprising:

a replaceable consumable component;

a readable data storage device located in or on the replaceable consumable component;

a data reading device in or on the torch for reading the data storage device; and

a data transfer mechanism enabling communication between the data reading device and the controller, wherein the data storage device contains data for the operation of the thermal processing system.

10. The torch of claim 9, wherein the data transfer mechanism comprises a wireless connection.

11. The torch of claim 9, wherein the readable data storage device is rewriteable.

12. The torch of claim 11, wherein the readable data storage device is writable while in service and/or while disposed within the torch.

13. The torch of claim 9, wherein the data comprises a cutting program.

14. The torch of claim 9, wherein the data is configured to produce an altered performance characteristic of the thermal processing system.

15. The torch of claim 14, wherein the altered performance characteristic comprises a better cut quality capability relative to an original cutting capability that would be possible using a substantially similar replaceable consumable component that does not transfer the data.

16. The torch of claim 9, wherein the data comprises a firmware update for the thermal processing system.

17. The torch of claim 9, wherein the data reading device comprises an RFID reading device.

18. A torch for a cutting or welding process, coupled to a controller, the torch comprising:

a receptacle within the torch, the torch being configured to receive a replacement consumable component;

a data reading device in or on the torch; and

a data transfer mechanism providing communication capabilities between the torch and the controller.

19. The torch of claim 18, wherein the data reading device is configured to communicate with a data storage device in or on a consumable component disposed in the torch.

20. The torch of claim 19, wherein the data reading device is also a data writing device configured to write data to the data storage device.

21. A method for at least partially controlling a process of a cutting or welding system, the method comprising:

providing a consumable having a data tag containing operating parameters;

assembling the consumable into a tool of the cutting or welding system;

communicating the operating parameters to a control device of the tool; and

controlling the cutting or welding process in accordance with operating parameters.

22. The method of claim 21, wherein the operating parameters comprise a cutting program.

23. A method for providing operating data to a cutting or welding system using a replaceable consumable component comprising a readable data storage device, the method comprising:

facilitating communication between the readable data storage device and a data reading device of the cutting or welding system; and

transferring operating data at least partially defining the operating parameter from the readable data storage device to the data reading device, the operating data being configured to affect an operation of the cutting or welding system.

24. The method of claim 23, wherein the readable data storage device comprises a first readable data storage device of a first replaceable consumable component and the data reading device comprises at least one data reading device of the cutting or welding system;

and

the operating data comprises a first set of operating data from the first readable data storage device, further comprising;

facilitating communication between a second readable data storage device of a second replaceable consumable component and one of the at least one data reading devices of the cutting or welding system; and

transferring a second set of operating data from the second readable data storage device to one of the at least one data reading devices, the second set of operating data being configured to adjust the operation of the cutting or welding system.

25. The method of claim 24, wherein a combination of the first set of operating data and second set of operating data are required to fully operate the cutting or welding system.

26. The method of claim 23, wherein the replaceable consumable component is a first consumable component and the cutting or welding system is further configured to identify a second consumable component based on physical features of the second consumable component.

27. The method of claim 26, wherein identifying the second consumable component based on physical features of the second consumable component comprises measuring a gas flow through the second consumable component.

28. The method of claim 27, wherein the measuring the gas flow comprises:

directing a gas flow through a flow-restriction element associated with the second consumable component disposed within the cutting or welding system;

determining a first pressure of the gas flow at a location upstream relative to the flow-restriction element;

determining a second pressure of the gas flow at a location downstream from the flow-restriction element;

determining a flow rate of the gas flow passing through the flow-restriction element; and

using the first pressure, the second pressure, and the flow rate to identify the second consumable component.

29. The method of claim 23, wherein the operating data comprises a firmware update for the cutting or welding system.

30. The method of claim 29, further comprising determining a firmware version being used by the cutting or welding system;

and comparing the firmware version being used with a firmware version of the firmware update.

31. The method of claim 23, wherein affect includes fully replacing the control software.

32. A method for storing information on a replaceable consumable component used in a thermal processing machine while the replaceable consumable component is in an operation configuration, the method comprising:

configuring a rewritable data storage device of the replaceable consumable component for communication with a data writing device of the thermal processing machine; and

writing the information by the data writing device to the rewritable data storage device.

40. The method of claim 32, wherein the operation configuration comprises the thermal processing machine being in use.

33. The method of 32, wherein the information is associated with a previous use of the replaceable consumable component.

34. The method of claim 33, wherein the information comprises information relating to a time duration of the previous use of the replaceable consumable component.

35. The method of claim 33, wherein the information comprises information relating to a failure or error of a torch, the replaceable consumable component, or the thermal processing machine.

36. The method of claim 33, wherein the information is repeatedly rewritten while in operation.

37. The method of claim 33, wherein the information comprises information relating to a frequency of use of the thermal processing machine.

38. The method of claim 33, wherein the information comprises information relating to a number of cutting cycles for which the replaceable consumable component has been used.

39. The method of claim 33, wherein the information comprises information relating to operating parameters of the thermal processing machine during the previous use of the replaceable consumable component.