System and method for monitoring and controlling energy usage

• US 7,208,697 B2
• Filed: 05/20/2004
• Issued: 04/24/2007
• Est. Priority Date: 05/20/2004
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Blankenship, George D., Mason, Seth
• Primary Examiner(s): Shaw; Clifford C.
• Application Number:
  US10/850,536
• Publication Number:
  US 20050258154A1
• Time in Patent Office: 1,069 Days
• Field of Search: 219/130.01, 219/130.21, 219/130.33, 307/38, 307/39
• US Class Current: 219/130.21
• CPC Class Codes: B23K 9/0953 using computing means

Abstract

A welding control system to monitor the energy consumption of a plurality of welders. The welding control system controls the operation of one or more welders based upon the energy information received from one or more energy monitoring devices.

Claims

1. A welding control system to monitor the energy consumption of a plurality of welders comprising a plurality of energy monitoring devices and a controller designed to receive data from said plurality of energy monitoring devices, each of said energy monitoring devices monitoring energy consumption from at least one of said welders, said controller generating information concerning energy consumption of a plurality of said welders, said controller preventing or delaying a startup of at least one welder if such startup of such welder will cause said monitored energy consumption of said monitored welders to exceed a predefined value.

2. The welding system as defined in claim 1, wherein said information concerning energy consumption generated by said controller includes real time information relating to energy consumption of a single welder, real time information relating to energy consumption of a plurality of welders, historical information relating to energy consumption of a single welder, historical information relating to energy consumption of a plurality of welders, information relating to future energy consumption of a single welder, information relating to future energy consumption of a plurality of welders, or combinations thereof.

3. The welding system as defined in claim 2, wherein said controller includes a computer, said computer including hardware to generate information relating to energy consumption of at least one welder, software to generate information relating to energy consumption of at least one welder, or combinations thereof.

4. The welding system as defined in claim 3, wherein a plurality of energy monitoring devices are designed to send data to said controller by an IR transmitter, a RF transmitter, a microwave transmitter, a phone line, computer cable, an electric wire, a fiberoptic cable, a USB cable, a coaxial cable, or combinations thereof.

5. The welding system as defined in claim 4, wherein a plurality of energy monitoring devices send data to said controller via an ethernet.

6. The welding system as defined in claim 2, wherein a plurality of energy monitoring devices are designed to send data to said controller by an IR transmitter, a RF transmitter, a microwave transmitter, a phone line, computer cable, an electric wire, a fiberoptic cable, a USB cable, a coaxial cable, or combinations thereof.

7. The welding system as defined in claim 2, wherein said controller generates a signal to activate, deactivate or combinations thereof at least one welder, said signal is at least partially based on said data from a plurality of said energy monitoring devices.

8. The welding system as defined in claim 2, wherein said controller is networked to at least one other controller, at least one of said controllers sending information to, receiving information from or combinations thereof a master controller.

9. The welding system as defined in claim 2, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

10. The welding system as defined in claim 2, wherein at least one operating parameter of at least one or said welders is at least partially set, changed or combinations thereof by said controller.

11. The welding system as defined in claim 1, wherein said controller includes a computer, said computer including hardware to generate information relating to energy consumption of at least one welder, software to generate information relating to energy consumption of at least one welder, or combinations thereof.

12. The welding system as defined in claim 11, wherein a plurality of energy monitoring devices are designed to send data to said controller by an IR transmitter, a RF transmitter, a microwave transmitter, a phone line, computer cable, an electric wire, a fiberoptic cable, a USB cable, a coaxial cable, or combinations thereof.

13. The welding system as defined in claim 12, wherein said controller generates a signal to activate, deactivate or combinations thereof at least one welder, said signal is at least partially based on said data from a plurality of said energy monitoring devices.

14. The welding system as defined in claim 13, wherein said signal generated by said controller to activate, deactivate or combinations thereof at least one of said welders is at least partially based on current energy demand by a plurality of said welders, anticipated energy demand by a plurality of said welders, energy charge for operating a plurality of said welders during a certain period of time, demand charge for operating a plurality of welders during a certain period of time, or combinations thereof.

15. The welding system as defined in claim 14, wherein said controller is networked to at least one other controller, at least one of said controllers sending information to, receiving information from or combinations thereof a master controller.

16. The welding system as defined in claim 15, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

17. The welding system as defined in claim 16, wherein at least one operating parameter of at least one or said welders is at least partially set, changed or combinations thereof by said controller.

18. The welding system as defined in claim 17, wherein said controller beginning startup of at least one of said welders that has been prevented or delayed from startup when said startup of said welder will not cause said monitored energy consumption to exceed a predefined value.

19. The welding system as defined in claim 17, wherein said controller beginning startup of at least one of said welders, terminating operation of at least one of said welders, or combinations thereof based at least partially on the priority of operation of a particular welder, production criteria for a particular welder in a production process, inventory levels of a particular welder, production quotas of a particular welder, operational status of a particular welder, or combinations thereof.

20. The welding system as defined in claim 5, wherein said controller generates a signal to activate, deactivate or combinations thereof at least one welder, said signal is at least partially based on said data from a plurality of said energy monitoring devices.

21. The welding system as defined in claim 20, wherein said signal generated by said controller to activate, deactivate or combinations thereof at least one of said welders is at least partially based on current energy demand by a plurality of said welders, anticipated energy demand by a plurality of said welders, energy charge for operating a plurality of said welders during a certain period of time, demand charge for operating a plurality of welders during a certain period of time, or combinations thereof.

22. The welding system as defined in claim 21, wherein said controller is networked to at least one other controller, at least one of said controllers sending information to, receiving information from or combinations thereof a master controller.

23. The welding system as defined in claim 22, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

24. The welding system as defined in claim 23, wherein at least one operating parameter of at least one or said welders is at least partially set, changed or combinations thereof by said controller.

25. The welding system as defined in claim 24, wherein said controller beginning startup of at least one of said welders that startup has been interrupted when said startup of said welder will not cause said monitored energy consumption to exceed a predefined value.

26. The welding system as defined in claim 25, wherein said controller beginning startup of at least one of said welders, terminating operation of at least one of said welders, or combinations thereof based at least partially on the priority of operation of a particular welder, production criteria for a particular welder in a production process, inventory levels of a particular welder, production quotas of a particular welder, operational status of a particular welder, or combinations thereof.

27. The welding system as defined in claim 24, wherein said controller beginning startup of at least one of said welders, terminating operation of at least one of said welders, or combinations thereof based at least partially on the priority of operation of a particular welder, production criteria for a particular welder in a production process, inventory levels of a particular welder, production quotas of a particular welder, operational status of a particular welder, or combinations thereof.

28. The welding system as defined in claim 11, wherein said controller generates a signal to activate, deactivate or combinations thereof at least one welder, said signal is at least partially based on said data from a plurality of said energy monitoring devices.

29. The welding system as defined in claim 11, wherein said controller is networked to at least one other controller, at least one of said controllers sending information to, receiving information from or combinations thereof a master controller.

30. The welding system as defined in claim 11, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

31. The welding system as defined in claim 11, wherein at least one operating parameter of at least one or said welders is at least partially set, changed or combinations thereof by said controller.

32. The welding system as defined in claim 1, wherein a plurality of energy monitoring devices are designed to send data to said controller by an IR transmitter, a RF transmitter, a microwave transmitter, a phone line, computer cable, an electric wire, a fiberoptic cable, a USB cable, a coaxial cable, or combinations thereof.

33. The welding system as defined in claim 32, wherein a plurality of energy monitoring devices send data to said controller via an ethernet.

34. The welding system as defined in claim 1, wherein said controller generates a signal to activate, deactivate or combinations thereof at least one welder, said signal is at least partially based on said data from a plurality of said energy monitoring devices.

35. The welding system as defined in claim 34, wherein said signal generated by said controller to activate, deactivate or combinations thereof at least one of said welders is at least partially based on current energy demand by a plurality of said welders, anticipated energy demand by a plurality of said welders, energy charge for operating a plurality of said welders during a certain period of time, demand charge for operating a plurality of welders during a certain period of time, or combinations thereof.

36. The welding system as defined in claim 1, wherein said controller is networked to at least one other controller, at least one of said controllers sending information to, receiving information from or combinations thereof a master controller.

37. The welding system as defined in claim 1, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

38. The welding system as defined in claim 1, wherein at least one operating parameter of at least one or said welders is at least partially set, changed or combinations thereof by said controller.

39. The welding system as defined in claim 1, wherein said controller beginning startup of at least one of said welders that has been prevented or delayed from startup when said startup of said welder will not cause said monitored energy consumption to exceed a predefined value.

40. The welding system as defined in claim 1, wherein said controller beginning startup of at least one of said welders, terminating operation of at least one of said welders, or combinations thereof based at least partially on the priority of operation of a particular welder, production criteria for a particular welder in a production process, inventory levels of a particular welder, production quotas of a particular welder, operational status of a particular welder, or combinations thereof.

41. A method of monitoring the energy consumption of a plurality of welders comprising:

a) providing at least one energy monitoring device;

b) at least partially monitoring energy consumption of said plurality of welders by said at least one energy monitoring device;

c) providing a controller;

d) sending data from said at least one energy monitoring device to said controller; and

,

e) at least partially controlling at least one of said welders at least partially on information received by said controller, said step of at least partially controlling including the step of preventing or delaying a startup of at least one welder of such startup of such welder will cause energy consumption of said monitored welders to exceed a predefined value.

42. The method as defined in claim 41, wherein said controller generates information concerning energy consumption of a plurality of said welders.

43. The method as defined in claim 42, wherein said information concerning energy consumption generated by said controller includes real time information relating to energy consumption of a single welder, real time information relating to energy consumption of a plurality of welders, historical information relating to energy consumption of a single welder, historical information relating to energy consumption of a plurality of welders, information relating to future energy consumption of a single welder, information relating to future energy consumption of a plurality of welders, or combinations thereof.

44. The method as defined in claim 43, wherein at least one of said energy monitoring devices sends data to said controller by an IR transmitter, a RF transmitter, a microwave transmitter, a phone line, computer cable, an electric wire, a fiberoptic cable, a USB cable, a coaxial cable, or combinations thereof.

45. The method as defined in claim 44, wherein at least one energy monitoring device and said controller are connected via an ethernet.

46. The method as defined in claim 45, including the step of activating, deactivating or combinations thereof at least one welder at least partially based on said data from said energy monitoring devices.

47. The method as defined in claim 46, wherein said step of activating, deactivating or combinations thereof at least one of said welders is at least partially based on current energy demand by a plurality of said welders, anticipated energy demand by a plurality of said welders, energy charge for operating a plurality of said welders during a certain period of time, demand charge for operating a plurality of welders during a certain period of time, or combinations thereof.

48. The method as defined in claim 47, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

49. The method as defined in claim 48, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

50. The method as defined in claim 42, including the step of activating, deactivating or combinations thereof at least one welder at least partially based on said data from said energy monitoring devices.

51. The method as defined in claim 42, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

52. The method as defined in claim 41, wherein said information concerning energy consumption generated by said controller includes real time information relating to energy consumption of a single welder, real time information relating to energy consumption of a plurality of welders, historical information relating to energy consumption of a single welder, historical information relating to energy consumption of a plurality of welders, information relating to future energy consumption of a single welder, information relating to future energy consumption of a plurality of welders, or combinations thereof.

53. The method as defined in claim 52, including the step of activating, deactivating or combinations thereof at least one welder at least partially based on said data from said energy monitoring devices.

54. The method as defined in claim 53, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

55. The method as defined in claim 54, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

56. The method as defined in claim 52, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

57. The method as defined in claim 41, wherein at least one of said energy monitoring devices sends data to said controller by an IR transmitter, a RF transmitter, a microwave transmitter, a phone line, computer cable, an electric wire, a fiberoptic cable, a USB cable, a coaxial cable, or combinations thereof.

58. The method as defined in claim 41, wherein at least one energy monitoring device and said controller are connected via an ethernet.

59. The method as defined in claim 41, including the step of activating, deactivating or combinations thereof at least one welder at least partially based on said data from said energy monitoring devices.

60. The method as defined in claim 59, wherein said step of activating, deactivating or combinations thereof at least one of said welders is at least partially based on current energy demand by a plurality of said welders, anticipated energy demand by a plurality of said welders, energy charge for operating a plurality of said welders during a certain period of time, demand charge for operating a plurality of welders during a certain period of time, or combinations thereof.

61. The method as defined in claim 41, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

62. The method as defined in claim 41, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

63. The method as defined in claim 41, wherein at least one operating parameter of at least one of said welders is at least partially set, changed or combinations thereof by said controller.

64. The method as defined in claim 41, including the step of beginning startup of at least one of said welders that has been prevented or delayed from startup when startup of said welder will not cause said monitored energy consumption to exceed a predefined value.

65. The method as defined in claim 64, including the step of beginning startup of at least one of said welders, terminating operation of at least one of said welders, or combinations thereof based at least partially on the priority of operation of a particular welder, production criteria for a particular welder in a production process, inventory levels of a particular welder, production quotas of a particular welder, operational status of a particular welder, or combinations thereof.

66. The method as defined in claim 41, including the step of beginning startup of at least one of said welders, terminating operation of at least one of said welders, or combinations thereof based at least partially on the priority of operation of a particular welder, production criteria for a particular welder in a production process, inventory levels of a particular welder, production quotas of a particular welder, operational status of a particular welder, or combinations thereof.

67. A method of controlling the energy consumption of a plurality of energy consuming devices comprising:

a) obtaining energy consumption information from a plurality of said energy consuming devices;

b) totaling the energy consumption information of said plurality of said energy consuming devices;

c) comparing said totalized energy consumption to a reference value; and

,

d) preventing or delaying the startup of operation of at least one one or said energy consuming devices when said totalized energy consumption equals or exceeds said reference value.

68. The method as defined in claim 67, wherein said step of obtaining energy consumption information includes the connection of at least one of said energy consuming devices to an energy consumption monitor.

69. The method as defined in claim 68, wherein said step of totaling the energy consumption includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

70. The method as defined in claim 69, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

71. The method as defined in claim 70, wherein said energy consumption information includes real time information relating to energy consumption of a single energy consuming device, real time information relating to energy consumption of a plurality of energy consuming devices, historical information relating to energy consumption of a single energy consuming device, historical information relating to energy consumption of a plurality of energy consuming devices, information relating to future energy consumption of a single energy consuming device, information relating to future energy consumption of a plurality of energy consuming devices, or combinations thereof.

72. The method as defined in claim 71, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes coupling a plurality of said energy consuming devices to a network interface to establish a network connection between said plurality of energy consuming devices.

73. The method as defined in claim 72, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes exchange information between a plurality of said energy consuming devices and the remote system.

74. The method as defined in claim 73, including the step of monitoring at least one welding function of a plurality of energy consuming devices and coordinating, controlling or combinations thereof a plurality of said energy consuming devices based at least partially on said monitored energy consuming device functions.

75. The method as defined in claim 68, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

76. The method as defined in claim 68, wherein said energy consumption information includes real time information relating to energy consumption of a single energy consuming device, real time information relating to energy consumption of a plurality of energy consuming devices, historical information relating to energy consumption of a single energy consuming device, historical information relating to energy consumption of a plurality of energy consuming devices, information relating to future energy consumption of a single energy consuming device, information relating to future energy consumption of a plurality of energy consuming devices, or combinations thereof.

77. The method as defined in claim 68, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes coupling a plurality of said energy consuming devices to a network interface to establish a network connection between said plurality of energy consuming devices.

78. The method as defined in claim 68, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes exchange information between a plurality of said energy consuming devices and the remote system.

79. The method as defined in claim 68, including the step of monitoring at least one welding function of a plurality of energy consuming devices and coordinating, controlling or combinations thereof a plurality of said energy consuming devices based at least partially on said monitored energy consuming device functions.

80. The method as defined in claim 67, wherein said step of totaling the energy consumption includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

81. The method as defined in claim 80, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

82. The method as defined in claim 80, wherein said energy consumption information includes real time information relating to energy consumption of a single energy consuming device, real time information relating to energy consumption of a plurality of energy consuming devices, historical information relating to energy consumption of a single energy consuming device, historical information relating to energy consumption of a plurality of energy consuming devices, information relating to future energy consumption of a single energy consuming device, information relating to future energy consumption of a plurality of energy consuming devices, or combinations thereof.

83. The method as defined in claim 80, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes coupling a plurality of said energy consuming devices to a network interface to establish a network connection between said plurality of energy consuming devices.

84. The method as defined in claim 80, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes exchange information between a plurality of said energy consuming devices and the remote system.

85. The method as defined in claim 80, including the step of monitoring at least one welding function of a plurality of energy consuming devices and coordinating, controlling or combinations thereof a plurality of said energy consuming devices based at least partially on said monitored energy consuming device functions.

86. The method as defined in claim 67, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

87. The method as defined in claim 67, wherein said energy consumption information includes real time information relating to energy consumption of a single energy consuming device, real time information relating to energy consumption of a plurality of energy consuming devices, historical information relating to energy consumption of a single energy consuming device, historical information relating to energy consumption of a plurality of energy consuming devices, information relating to future energy consumption of a single energy consuming device, information relating to future energy consumption of a plurality of energy consuming devices, or combinations thereof.

88. The method as defined in claim 67, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes coupling a plurality of said energy consuming devices to a network interface to establish a network connection between said plurality of energy consuming devices.

89. The method as defined in claim 67, wherein said step of obtaining energy consumption information from a plurality of said energy consuming devices includes exchange information between a plurality of said energy consuming devices and the remote system.

90. The method as defined in claim 67, including the step of monitoring at least one welding function of a plurality of energy consuming devices and coordinating, controlling or combinations thereof a plurality of said energy consuming devices based at least partially on said monitored energy consuming device functions.

91. The method as defined in claim 67, including the step of beginning startup of at least one of said energy consuming devices that has been prevented or delayed from startup when startup of said energy consuming devices will not cause said monitored energy consumption to exceed a predefined value.

92. The method as defined in claim 91, including the step of beginning startup of at least one of said energy consuming devices, terminating operation of at least one of said energy consuming devices, or combinations thereof based at least partially on the priority of operation of a particular energy consuming device, production criteria for a particular energy consuming device in a production process, inventory levels of a particular energy consuming device, production quotas of a particular energy consuming device, operational status of a particular energy consuming device, or combinations thereof.

93. The method as defined in claim 67, including the step of beginning startup of at least one of said energy consuming devices, terminating operation of at least one of said energy consuming devices, or combinations thereof based at least partially on the priority of operation of a particular energy consuming device, production criteria for a particular energy consuming device in a production process, inventory levels of a particular energy consuming device, production quotas of a particular energy consuming device, operational status of a particular energy consuming device, or combinations thereof.

94. An apparatus to control the energy consumption of a plurality of welders comprising at least one energy monitor to monitor the energy consumption information of said plurality of welders, a controller that totalizes the energy consumption information of a plurality of said welders and compares the totalized energy consumption to a reference value, said controller creating an operating signal to prevent or delay startup of at least one of said welders when said totalized energy consumption equals or exceeds said reference value.