Automated System for Machine Set-Up of Welding Power Sources and Welding Systems

• US 20140251969A1
• Filed: 02/27/2014
• Published: 09/11/2014
• Est. Priority Date: 03/11/2013
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Luck, John, Kowaleski, Anthony J., Casner, Bruce A., Stoner, Collin
• Granted Patent: US 10,213,861 B2
• Time in Patent Office: Days
• US Class Current: 219/130.21
• CPC Class Codes: B23K 9/09 Arrangements or circuits for arc welding with pulsed current or voltage
• CPC Class Codes: B23K 9/1043 characterised by the electric circuit B23K9/1012 takes precedence
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R

Abstract

A system for re-configuring a welding system provides the ability to download applications to a welding power source or system, and to store the configuration data and applications to one or more of a series of welders, thereby simplifying configuration and re-configuration of power sources.

Claims

1. A welding power source comprising:

a power supply for generating welding power;

a memory storing weld system configuration data and welding process application code for controlling the power supply;

a communications device configured for communications with an external computerized device in communication with a memory storing a plurality of welding process application codes for controlling the power supply for and corresponding advisory data describing the welding process application codes;

and

a controller operatively coupled to the power supply, the communications device and the memory, the controller programmed to access and display the data describing the welding process application codes, to retrieve a selected one of the welding process application codes from the external computerized device, and to store the welding process application code in the memory, wherein the controller accesses the welding process application code to control the power supply.

2. The welding power source of claim 1, wherein the selected welding process application code controls the power supply to provide a pulsed output having peak and background voltages or amperages.

3. The welding power source of claim 1, wherein the selected welding process application code provides a sequenced weld including at least one timed sequence segment.

4. The welding power source of claim 1, wherein the selected welding process application configures a communications port for communications between the controller and an external automated welding controller.

5. The welding power source of claim 4, wherein the communications port comprises a connector for use by the controller to access a remote trigger function.

6. The welding power source of claim 4, wherein communications port comprises a serial link for communicating with the automated welding controller.

7. The welding power source of claim 6, wherein the communications port communicates over at least one of a RS-232, RS-485, Bluetooth, or RF protocol.

8. The welding power source of claim 1, wherein the selected welding process application code controls the power supply to produce an AC waveform at the welding power output.

10. The welding power source of claim 1, wherein the selected welding process application code controls the power supply to adjust a frequency of an AC welding power output.

11. The welding power source of claim 1, further comprising a user interface including a display in communication with the controller, and wherein the advisory data is accessible from at least one of the user interface and the external computerized device.

12. The welding power source of claim 1, wherein the selected welding process application code enables selection of timed weld sequence parameters.

13. The welding power source of claim 1, wherein the advisory data explains the welding process application code on a weld.

14. A method for configuring a welding power source including a controller and a memory for use in a welding system including the welding power source and at least one peripheral device to communicate with the at least one peripheral device, the method comprising:

providing a database identifying peripheral equipment for connection to the welding power source;

communicatively coupling the welding power source to the database;

prompting a user to identify at least one peripheral device for connection to the welding power source;

retrieving communications data for communications between the controller in the welding power source and the peripheral equipment;

storing the communications data in the memory of the welding power source;

identifying a connection point for connecting the peripheral device to the welding power source; and

transmitting at least one test signal through the connection point between the peripheral equipment and the welding power source to verify communications.

15. The method as recited in claim 14, wherein the step of identifying a connection point further comprises prompting a user to connect the peripheral equipment to the welding power source.

16. The method as recited in claim 14, wherein the step of transmitting at least one test signal further comprises prompting the user to activate communications between the identified peripheral equipment and the welding power supply through the connection.

17. The method as recited in claim 14, further comprising the step of identifying the peripheral equipment in the database with at least one of a manufacturer name, a brand name, and a stock keeping unit (SKU) number.

18. The method as recited in claim 14, wherein the step of transmitting at least one test signal further comprises the steps of prompting the user to connect the peripheral equipment to the welding power supply and prompting the user to activate one or more function to verify communications between the peripheral equipment and the welding power source.

19. The method as recited in claim 14, further comprising the step of providing advisor data to the user illustrating the connections to be made between the peripheral equipment and the welding power source.

20. The method as recited in claim 14, further comprising the step of prompting the user to customize connections to the peripheral equipment when the communications are not verified in the test.