Wireless communication network sensor information for control of industrial equipment in harsh environments

• US 9,270,520 B2
• Filed: 03/12/2013
• Issued: 02/23/2016
• Est. Priority Date: 08/17/2012
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Dina, Daniel, Downie, Kathy Lee
• Primary Examiner(s): Hussain, Tauqir
• Application Number:
  US13/795,970
• Publication Number:
  US 20140052832A1
• Time in Patent Office: 1,078 Days
• US Class Current: 1/1
• CPC Class Codes: B23K 9/1087 Arc welding using remote control
• CPC Class Codes: H04L 41/00 Arrangements for maintenance, administration or management of data switching networks, e.g. of packet switching networks
• CPC Class Codes: H04W 12/06 Authentication
• CPC Class Codes: H04W 76/10 Connection setup
• CPC Class Codes: H04W 84/18 Self-organising networks, e.g. ad-hoc networks or sensor networks
• CPC Class Codes: Y04S 40/20 Information technology specific aspects, e.g. CAD, simulation, modelling, system security

Abstract

In certain embodiments, a system includes a master node device. The master node device includes communication circuitry configured to facilitate communication with a welding power supply unit via a long-range communication link, and to facilitate wireless communication with one or more welding-related devices via a short-range wireless communication network. The master node device also includes control circuitry configured to receive sensor data from one or more sensors within a physical vicinity of the short-range wireless communication network, and to route the sensor data to final destinations for the one or more sensors.

Claims

1. A system, comprising:

a master node device comprising;

communication circuitry configured to facilitate communication with a welding power supply unit via a communication link, and to facilitate wireless communication with one or more welding-related devices via a wireless communication network; and

control circuitry configured to receive sensor data from one or more sensors within a physical vicinity of the wireless communication network, to route the sensor data to final destinations for the one or more sensors, and to provide a capabilities list to the one or more sensors upon request from the one or more sensors, wherein the capabilities list includes whether the master node device has access to the World Wide Web (WWW), if the master node device is aware of other master node devices that have access to the WWW, a lifetime duration of the wireless communication network, a battery status of the master node device, and a sleep period of the wireless communication network, wherein the communication link has a greater transmission range than the wireless communication network.

2. The system of claim 1, wherein the control circuitry is configured to allow association of the one or more sensors with the wireless communication network only if the sensors include authorization credentials that indicate the sensors may be used with the master node device.

3. The system of claim 2, wherein the authorization credentials include at least a media access control (MAC) address and a function code of the sensors.

4. The system of claim 1, wherein the control circuitry is configured to track a number of packets of sensor data to be sent from each of the one or more sensors, and to perform security and check sums on the sensor data received from each of the one or more sensors before routing the sensor data to its final destination.

5. The system of claim 1, wherein the control circuitry is configured to reprogram operating parameters of each of the one or more sensors based on input from a server at the final destination for the respective sensor, wherein the operating parameters include sensor data collection timing parameters, sleep and wake timing parameters, and final destination IP address parameters.

6. The system of claim 1, wherein the control circuitry is configured to provide a server at the final destination of a sensor of the one or more sensors with information relating to the sensor having the final destination.

7. The system of claim 1, wherein the one or more welding-related devices comprise a welding wire feeder.

8. The system of claim 1, wherein the one or more welding-related devices comprise a welding torch.

9. The system of claim 1, wherein the one or more welding-related devices comprise a welding helmet.

10. The system of claim 1, wherein the one or more welding-related devices comprise a welding pendant.

11. The system of claim 1, wherein the one or more welding-related devices comprise a welding foot pedal.

12. The system of claim 1, wherein a welding-related device of the one or more welding-related devices comprises the master node device.

13. The system of claim 1, wherein the communication circuitry includes radio frequency (RF) transmitters and sensors.

24. The system of claim 1, wherein the wireless communication network comprises a wireless communication network having a transmission range of approximately 20-25 feet from the master node device, and wherein the communication link comprises a wireless communication link having a transmission range of approximately 300 feet or more from the master node device to the welding power supply unit.

14. A method, comprising:

wirelessly communicating between one or more welding-related devices and a master node device via a wireless communication network;

communicating between the master node device and a welding power supply unit via a communication link;

receiving sensor data from one or more sensors within a physical vicinity of the wireless communication network;

routing the sensor data to final destinations for the one or more sensors; and

providing a capabilities list from the master node device to the one or more sensors upon request from the one or more sensors, wherein the capabilities list includes whether the master node device has access to the World Wide Web (WWW), if the master node device is aware of other master node devices that have access to the WWW, a lifetime duration of the wireless communication network, a battery status of the master node device, and a sleep period of the wireless communication network, wherein the communication link has a greater transmission range than the wireless communication network.

15. The method of claim 14, comprising allowing association of the one or more sensors with the wireless communication network only if the sensors include authorization credentials that indicate the sensors may be used with the master node device.

16. The method of claim 15, wherein the authorization credentials include at least a media access control (MAC) address and a function code of the sensors.

17. The method of claim 14, comprising using the mater node device to track a number of packets of sensor data to be sent from each of the one or more sensors with the master node device, and perform security and check sums on the sensor data received from each of the one or more sensors before routing the sensor data to its final destination from the master node device.

18. The method of claim 14, comprising reprogramming operating parameters of a sensor of the one or more sensors based on input from a server at the final destination for the sensor, wherein the operating parameters include sensor data collection timing parameters, sleep and wake timing parameters, and final destination IP address parameters.

19. The method of claim 14, comprising providing a server at the final destination of a sensor of the one or more sensors with information relating to the sensor having the final destination.

20. The method of claim 14, wherein the wireless communication network comprises a wireless communication network having a transmission range of approximately 20-25 feet from the master node device, and wherein the communication link comprises a wireless communication link having a transmission range of approximately 300 feet or more from the master node device to the welding power supply unit.

21. The method of claim 14, wherein the one or more welding-related devices comprise a welding wire feeder, a welding torch, a welding helmet, a welding pendant, or a welding foot pedal.

22. The method of claim 14, wherein a welding-related device of the one or more welding-related devices comprises the master node device.

23. A wireless communication network, comprising:

one or more welding-related devices, wherein the one or more welding-related devices comprise a welding wire feeder, a welding torch, a welding helmet, a welding pendant, or a welding foot pedal;

a welding power supply unit configured to convert power from a power grid to power for a welding operation performed using the one or more welding-related devices; and

a master node device configured to facilitate wireless communication between the one or more welding-related devices and the master node device via a wireless communication network, to facilitate communication between the master node device and the welding power supply unit via a communication link, to receive sensor data from one or more sensors within a physical vicinity of the wireless communication network, to route the sensor data to final destinations for the one or more sensors, and to provide a capabilities list to the one or more sensors upon request from the one or more sensors, wherein the capabilities list includes whether the master node device has access to the World Wide Web (WWW), if the master node device is aware of other master node devices that have access to the WWW, a lifetime duration of the wireless communication network, a battery status of the master node device, and a sleep period of the wireless communication network, wherein the communication link has a greater transmission range than the wireless communication network.

25. The wireless communication network of claim 23, wherein the wireless communication network comprises a wireless communication network having a transmission range of approximately 20-25 feet from the master node device, and wherein the communication link comprises a wireless communication link having a transmission range of approximately 300 feet or more from the master node device to the welding power supply unit.