Force Sensing Control Apparatus For Welding Machines

• US 20160193682A1
• Filed: 01/07/2015
• Published: 07/07/2016
• Est. Priority Date: 01/07/2015
• Status: Active Grant

• Current Assignee: Tigbutton LLC
• Original Assignee: David Vogel, Gary F. Skinner
• Inventors: Vogel, David, Skinner, Gary F.
• Granted Patent: US 10,987,751 B2
• Time in Patent Office: Days
• CPC Class Codes: B23K 9/1087 Arc welding using remote control
• CPC Class Codes: B23K 9/167 and of a non-consumable electrode
• CPC Class Codes: B23K 9/296 using non-consumable electrodes
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R

Abstract

Apparatus for allowing a welder to control the output power of a welding machine, and thus its arc power by applying force to a surface of a force sensing transducer assembly. The force sensing transducer assembly generates a force signal based upon the force applied, for example by reducing the resistance within the force sensing transducer assembly. A control interface module then receives the force signal and controls the welding machine power output based upon the force signal. The welder may set the range of force to change the arc power by setting a minimum amount of force to actuate the welding machine and a maximum force that increases the output power of the welding machine (force below the minimum does not actuate the welding machine and force above the maximum does not increase the welding machine power above a certain level). A user interface provides potentiometers for setting the minimum and maximum, and also provides indicators such as LEDs for indicating whether the welding machine is turned on and actuated. The force signal may be transmitted over a cable or wirelessly.

Claims

1. Force sensing control apparatus for welding machines comprising:

a force sensing transducer assembly for sensing force applied by a welder and for generating a force signal;

a control interface module for generating a welding machine control signal based upon the force signal, the welding machine control signal configured to control an operation parameter of a welding machine; and

a transmission medium for transmitting the force signal to the control interface module.

2. The apparatus of claim 1, further comprising an interface for setting an effective range of the force signal to control the operation parameter.

3. The apparatus of claim 2, wherein the operations parameter is the output power of the welding machine and wherein the interface comprises:

an actuation point sensitivity control for determining the minimum amount of force to configure the welding machine control signal to actuate the welding machine; and

a maximum force level control for determining the maximum amount of force that will configure the welding machine control signal to increase the output power of the welding machine;

wherein the actuation point sensitivity control and the maximum force level control are adjustable by a welder.

4. The apparatus of claim 3 further including an indicator of the welding machine control signal.

5. The apparatus of claim 1, further comprising an interface having an indicator of the welding machine control signal level.

6. The apparatus of claim 1, wherein the force sensing transducer assembly comprises:

a force transducer for converting force into a force signal; and

a surface configured for pressing by the welder in order to provide force to the force sensing transducer, the surface substantially fixed in place with respect to the force sensing transducer.

7. The apparatus of claim 6 wherein the force sensing transducer reduces resistance within the force sensing transducer assembly based upon the force;

and

wherein the force signal is based upon the reduced resistance within the force sensing transducer assembly.

8. The apparatus of claim 6 wherein the surface comprises a tactile button and further comprising a clip configured to attach the force sensing transducer assembly to a common form TIG torch in a manner to allow a welder to apply force to the tactile button using a desired portion of a hand of the welder.

9. The apparatus of claim 6 wherein the force sensing transducer assembly comprises a bite sensor and wherein the surface comprises a tactile button and wherein the bite sensor further comprises:

a second face on an opposing side of the force sensing transducer assembly from the tactile button; and

a resilient encapsulating coating surrounding the force sensing transducer assembly;

wherein the bite sensor is sized and configured for a welder to apply force by biting the tactile button and the second face.

10. The apparatus of claim 6 wherein the force sensing transducer assembly comprises a multipurpose sensor (“

puck”

) wherein the surface comprises a rigid top cover and further comprising;

an enclosure attached to the top cover and having a bottom;

wherein the “

puck”

is constructed and arranged for a welder to press the rigid top cover and the enclosure between a body part and a relatively rigid barrier in order to apply force to the top cover.

11. The apparatus of claim 6 wherein the transmission medium is wired.

12. The apparatus of claim 6 wherein the transmission medium is wireless.

13. The apparatus of claim 6 wherein the transmission medium is both wired and wireless

14. The apparatus of claim 1 wherein the transmission medium comprises one of the following:

wired;

wireless;

both wired and wireless.

15. The apparatus of claim 1 wherein the force sensing transducer assembly includes an array of force sensing transducers.

16. Force sensing control apparatus for a welding machine comprising:

means for sensing force applied by a body part of a welder;

means for generating a force signal based upon the sensed force;

means for generating a control signal based upon the force signal;

means for controlling a parameter of a welding machine based upon the control signal.

17. The apparatus of claim 16 wherein the parameter is output power of the welding machine and further comprising:

means for setting the minimum amount of force to configure the control signal to actuate the welding machine; and

means for setting the maximum amount of force that will configure the control signal to increase the output power of the welding machine.

18. The apparatus of claim 16 further comprising means for indicating to a welder the control signal state.

19. The method of controlling an operation parameter of a welding machine comprising the steps of:

(a) sensing the amount of force applied by a body part of a welder to a surface;

(b) generating a force signal based upon the amount of sensed force;

(c) generating a control signal based upon the force signal;

(d) controlling the operation parameter based upon the control signal.

20. The method of claim 19 further including the step of setting an effective range of the force signal to control the operation parameter.