Systems and methods for wireless control of an engine-driven welding power supply

• US 9,943,924 B2
• Filed: 03/28/2014
• Issued: 04/17/2018
• Est. Priority Date: 03/28/2014
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Denis, Marc Lee, Peotter, Benjamin G.
• Primary Examiner(s): Jennison, Brian
• Application Number:
  US14/229,271
• Publication Number:
  US 20150273607A1
• Time in Patent Office: 1,481 Days
• CPC Class Codes: B23K 9/1006 Power supply
• CPC Class Codes: B23K 9/1087 Arc welding using remote control
• CPC Class Codes: F02D 2041/228 Warning displays
• CPC Class Codes: F02D 2400/06 Small engines with electronic control, e.g. for hand held tools
• CPC Class Codes: F02D 29/06 peculiar to engines driving electric generators
• CPC Class Codes: F02D 31/001 Electric control of rotation speed
• CPC Class Codes: F02D 41/22 Safety or indicating devices for abnormal conditions in air/fuel ratio feedback systems F02D41/1495, in electric control linkage F02D11/107, in purge control systems F02M25/0809
• CPC Class Codes: F02D 41/266 the computer being backed-up or assisted by another circuit, e.g. analogue
• CPC Class Codes: F02N 11/0807 Remote means
• CPC Class Codes: F02N 11/0818 Conditions for starting or stopping the engine or for deactivating the idle-start-stop mode
• CPC Class Codes: F02N 11/12 Starting of engines by means of mobile, e.g. portable, starting sets
• CPC Class Codes: F02N 11/14 Starting of engines by means of electric starters with external current supply F02N11/12 takes precedence
• CPC Class Codes: F02N 2200/00 Parameters used for control of starting apparatus
• CPC Class Codes: F02N 2300/306 with external senders or receivers, e.g. receiving signals from traffic lights, other vehicles or base stations
• CPC Class Codes: H04L 63/062 for key distribution, e.g. centrally by trusted party cryptographic mechanisms or cryptographic arrangements for key distribution involving a central third party H04L9/0819
• CPC Class Codes: H04W 12/04 Key management, e.g. using generic bootstrapping architecture [GBA]
• CPC Class Codes: H04W 12/08 Access security
• CPC Class Codes: H04W 12/50 Secure pairing of devices
• CPC Class Codes: Y02D 30/70 in wireless communication networks
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y04S 40/20 : Information technology specific aspects, e.g. CAD, simulation, modelling, system security

Abstract

Embodiments described herein include wireless control of a welding power supply via portable electronic devices. In particular, operating parameters and statuses of the welding power supply may be modified by the portable electronic device, as well as be displayed on the portable electronic device. For example, in certain embodiments, the welding power supply may be an engine-driven welding power supply, and the portable electronic device may be configured to start and/or stop an engine of the engine-driven welding power supply. A pairing procedure may be used to pair the welding power supply and the portable electronic device in a wireless communication network. Furthermore, in certain embodiments, a method of prioritization of control between a control panel of the welding power supply and the portable electronic device may be implemented.

Claims

1. A welding power supply comprising:

a housing comprising a control panel configured to receive inputs from an operator;

a generator disposed within the housing and configured to generate power;

an engine disposed within the housing and configured to drive the generator;

power conversion circuitry disposed within the housing and configured to convert the power generated by the generator into output power for a welding operation; and

local control circuitry disposed within the housing and configured to wirelessly receive a control signal from remote control circuitry of a portable electronic device, and to control the welding power supply based at least in part on the received control signal;

wherein the local control circuitry is configured to set prioritization of control of the welding power supply between the portable electronic device and the control panel of the welding power supply, to prevent the control panel from controlling at least one parameter of the welding power supply when the portable electronic device is prioritized, and to prevent the portable electronic device from controlling the at least one parameter of the welding power supply when the control panel is prioritized.

2. The welding power supply of claim 1, wherein the remote control circuitry comprises a radio subsystem configured to wirelessly send and receive control signals to and from the local control circuitry using a signaling protocol.

3. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to start the engine, and to start the engine based at least in part on the received control signal.

4. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to stop the engine, and to stop the engine based on the received control signal.

5. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to control a speed of the engine, and to control the speed of the engine based at least in part on the received control signal.

6. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to control an engine run mode of the engine, and to control the engine run mode based at least in part on the received control signal.

7. The welding power supply of claim 1, wherein the portable electronic device comprises a display, the local control circuitry is configured to wirelessly send data relating to a fuel level of the engine to the remote control circuitry, and the remote control circuitry is configured to display the data on the display.

8. The welding power supply of claim 1, wherein the portable electronic device comprises a display, the local control circuitry is configured to wirelessly send data relating to a time to scheduled oil change for the engine to the remote control circuitry, and the remote control circuitry is configured to display the data on the display.

9. The welding power supply of claim 1, wherein the portable electronic device comprises a display, the local control circuitry is configured to wirelessly send data relating to total hours of use of the engine to the remote control circuitry, and the remote control circuitry is configured to display the data on the display.

10. The welding power supply of claim 1, wherein the portable electronic device comprises a display, the local control circuitry is configured to wirelessly send data relating to total hours of use of the welding power supply to the remote control circuitry, and the remote control circuitry is configured to display the data on the display.

11. The welding power supply of claim 1, wherein the portable electronic device comprises a display, the local control circuitry is configured to wirelessly send data relating to diagnostic messages or diagnostic codes for the welding power supply to the remote control circuitry, and the remote control circuitry is configured to display the data on the display.

12. The welding power supply of claim 1, wherein the portable electronic device comprises a display, the local control circuitry is configured to wirelessly send data relating to engine diagnostic messages or engine diagnostic codes for the engine to the remote control circuitry, and the remote control circuitry is configured to display the data on the display.

13. The welding power supply of claim 1, wherein the local control circuitry is configured to facilitate access by the remote control circuitry to an engine serial data bus of the engine.

14. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to control an operating parameter or status of an air compressor of the welding power supply, and to control the operating parameter or status based at least in part on the received control signal.

15. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to control an operating parameter or status of a hydraulic pump of the welding power supply, and to control the operating parameter or status based at least in part on the received control signal.

16. The welding power supply of claim 1, wherein the portable electronic device comprises a display, and the local control circuitry is configured to wirelessly send instructions to the remote control circuitry to display a nested graphical hierarchical structure of operating parameters and statuses of the welding power supply via the display.

17. The welding power supply of claim 1, wherein the remote control circuitry is configured to place the portable electronic device in a sleep mode, and to wirelessly send a control signal to the local control circuitry to place the welding power supply in a sleep mode while maintaining network pairing between the portable electronic device and the welding power supply.

18. The welding power supply of claim 17, wherein the remote control circuitry is configured to wake the portable electronic device from the sleep mode upon detection of activity on the portable electronic device, and to wirelessly send a control signal to the local control circuitry to wake the welding power supply from a sleep mode upon the detection of the activity on the portable electronic device.

19. The welding power supply of claim 17, wherein the local control circuitry is configured to wake the welding power supply from a sleep mode upon detection of activity on the welding power supply, and to wirelessly send a control signal to the remote control circuitry to wake the portable electronic device from the sleep mode upon the detection of the activity on the welding power supply.

20. The welding power supply of claim 1, wherein the local control circuitry is configured to place the welding power supply in a sleep mode, and to wirelessly send a control signal to the remote control circuitry to place the portable electronic device in a sleep mode while maintaining network pairing between the portable electronic device and the welding power supply.

21. The welding power supply of claim 20, wherein the local control circuitry is configured to wake the welding power supply from the sleep mode upon detection of activity on the welding power supply, and to wirelessly send a control signal to the remote control circuitry to wake the portable electronic device from a sleep mode upon the detection of the activity on the welding power supply.

22. The welding power supply of claim 20, wherein the remote control circuitry is configured to wake the portable electronic device from a sleep mode upon detection of activity on the portable electronic device, and to wirelessly send a control signal to the local control circuitry to wake the welding power supply from the sleep mode upon the detection of the activity on the portable electronic device.

23. The welding power supply of claim 1, wherein the portable electronic device comprises a memory medium, the local control circuitry is configured to wirelessly send data relating to one or more operating parameters and statuses of the welding power supply to the remote control circuitry for storage in the memory medium, and the remote control circuitry stores the data in the memory medium.

24. The welding power supply of claim 23, wherein the welding power supply comprises a memory medium, and the local control circuitry stores the data in the memory medium of the welding power supply.

25. The welding power supply of claim 1, wherein the portable electronic device comprises a memory medium, the local control circuitry is configured to wirelessly send data relating to a user-preferred welding process parameter for the welding power supply to the remote control circuitry for storage in the memory medium, and the remote control circuitry stores the data in the memory medium.

26. The welding power supply of claim 25, wherein the welding power supply comprises a memory medium, and the local control circuitry stores the data in the memory medium of the welding power supply.

27. The welding power supply of claim 1, wherein the local control circuitry and the remote control circuitry are configured to bi-directionally communicate information relating to a preset value for a parameter of the welding power supply, wherein the bi-directional communication includes only digital communication.

28. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to change a welding process type of the welding power supply, and to change the welding process type based on the received control signal.

29. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to change a current of the welding operation, and to change the current of the welding operation based at least in part on the received control signal.

30. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to change a voltage of the welding operation, and to change the voltage of the welding operation based at least in part on the received control signal.

31. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to add advanced welding process functionality to the welding power supply, and to add the advanced welding process functionality based on the received control signal.

32. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to change a welding arc control parameter of the welding power supply, and to change the welding arc control parameter based on the received control signal.

33. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to change a polarity of a welding process of the welding power supply, and to change the polarity of the welding process based on the received control signal.

34. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly receive a control signal from the remote control circuitry to change an operating status of a welding output of the welding power supply, and to change the operating status of the welding output based on the received control signal.

35. The welding power supply of claim 1, wherein the local control circuitry is configured to wirelessly send a control signal to the remote control circuitry to indicate a location of the portable electronic device, and the remote control circuitry is configured to indicate the location of the portable electronic device by activating an indicator on the portable electronic device.

36. The welding power supply of claim 1, wherein the portable electronic device is a cellular phone.

37. The welding power supply of claim 1, wherein the portable electronic device is a laptop computer.

38. The welding power supply of claim 1, wherein the portable electronic device is a tablet computer.

39. The welding power supply of claim 1, wherein the portable electronic device is a dedicated original equipment manufacturer (OEM) remote control device.

40. The welding power supply of claim 1, wherein the local control circuitry is configured to automatically start or automatically stop the engine based at least in part on detection of an event occurring in the welding power supply or a device coupled to the welding power supply.

41. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when a stick welding rod touches a grounded surface.

42. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when a welding arc is detected.

43. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when a trigger of a metal inert gas (MIG) welding torch is pressed.

44. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when a foot pedal is depressed.

45. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when a tungsten inert gas (TIG) welding torch touches a grounded surface.

46. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when an auxiliary load is detected.

47. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine upon detection of a change in pressure in a compressor of the welding power supply.

48. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine upon detection of a change in pressure in a hydraulic pump of the welding power supply.

49. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically start the engine when a power level of a battery of the welding power supply falls below a predetermined threshold.

50. The welding power supply of claim 40, wherein the local control circuitry is configured to automatically stop the engine after a given amount of time without activity in the welding power supply.

51. A welding power supply comprising:

a generator configured to generate power;

an engine configured to drive the generator;

power conversion circuitry configured to convert the power generated by the generator into output power for a welding operation;

a control panel configured to receive inputs from an operator; and

local control circuitry configured to wirelessly receive a control signal from remote control circuitry of a portable electronic device, and to control the welding power supply based at least in part on the received control signal;

wherein the local control circuitry is configured to set prioritization of control of the welding power supply between the portable electronic device and the control panel of the welding power supply, to prevent the control panel from controlling at least one parameter of the welding power supply when the portable electronic device is prioritized, and to prevent the portable electronic device from controlling the at least one parameter of the welding power supply when the control panel is prioritized.