System and method for monitoring and controlling energy usage

• US 20050258154A1
• Filed: 05/20/2004
• Published: 11/24/2005
• 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
• Granted Patent: US 7,208,697 B2
• Time in Patent Office: Days
• US Class Current: 219/130.10
• 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 at least one energy monitoring device and a controller designed to receive data from at least one of said 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.

2. The welding system as defined in claim 1, wherein said information concerning energy consumption generated by said controller including 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 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.

4. 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.

5. 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.

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 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.

8. The welding system as defined in claim 4, 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.

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

10. The welding system as defined in claim 8, wherein a plurality of energy monitoring devices send data to said controller via an ethernet.

11. 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.

12. 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.

13. The welding system as defined in claim 3, 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 7, 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.

15. The welding system as defined in claim 7, 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.

16. The welding system as defined in claim 11, 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.

17. The welding system as defined in claim 14, 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.

18. The welding system as defined in claim 15, 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.

19. 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.

20. 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.

21. The welding system as defined in claim 3, 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.

22. The welding system as defined in claim 17, 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 18, 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.

24. 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.

25. 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.

26. The welding system as defined in claim 3, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

27. 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.

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

29. 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.

30. 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.

31. The welding system as defined in claim 3, 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 27, 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.

33. The welding system as defined in claim 28, 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.

34. 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 at least one of said welders by said energy monitoring device;

c) providing a controller;

d) sending data from said 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.

35. The method as defined in claim 34, wherein said controller generates information concerning energy consumption of a plurality of said welders.

36. The method as defined in claim 34, 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.

37. The method as defined in claim 35, 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.

38. The method as defined in claim 34, 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.

39. The method as defined in claim 37, 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.

40. The method as defined in claim 34, wherein at least one energy monitoring device and said controller are connected via an ethernet.

41. The method as defined in claim 39, wherein at least one energy monitoring device and said controller are connected via an ethernet.

42. The method as defined in claim 34, 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.

43. The method as defined in claim 35, 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.

44. The method as defined in claim 36, 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.

45. 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.

46. The method as defined in claim 42, 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.

47. The method as defined in claim 45, 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 34, 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 35, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

50. The method as defined in claim 36, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

51. The method as defined in claim 44, 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 47, including the step of networking at least two controllers to monitor energy consumption by a plurality of welders.

53. The method as defined in claim 34, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

54. The method as defined in claim 51, wherein said controller monitors, controls or combinations thereof at least one operating parameter of at least one welder.

55. The method as defined in claim 52, 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 34, 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.

57. A method of controlling the energy consumption of a plurality of welders comprising:

a) obtaining energy consumption information from a plurality of said welders;

b) totaling the energy consumption information of said plurality of said welders;

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

,

d) terminating the operation of at least one welder when said totalized energy consumption equals or exceeds said reference value.

58. The method as defined in claim 57, wherein said step of obtaining energy consumption information includes the connection of at least one of said welders to an energy consumption monitor.

59. The method as defined in claim 57, wherein said step of totaling the energy consumption includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

60. The method as defined in claim 58, wherein said step of totaling the energy consumption includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

61. The method as defined in claim 57, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

62. The method as defined in claim 58, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

63. The method as defined in claim 59, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

64. The method as defined in claim 60, wherein said step of comparing said totalized energy includes the used of a microprocessor, a hard wired circuit, a software program or combinations thereof.

65. The method as defined in claim 57, wherein said energy consumption information 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.

66. The method as defined in claim 58, wherein said energy consumption information 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.

67. The method as defined in claim 59, wherein said energy consumption information 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.

68. The method as defined in claim 64, wherein said energy consumption information 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.

69. The method as defined in claim 57, wherein said step of obtaining energy consumption information from a plurality of said welders includes coupling a plurality of said welders to a network interface to establish a network connection between said plurality of welders.

70. The method as defined in claim 58, wherein said step of obtaining energy consumption information from a plurality of said welders includes coupling a plurality of said welders to a network interface to establish a network connection between said plurality of welders.

71. The method as defined in claim 59, wherein said step of obtaining energy consumption information from a plurality of said welders includes coupling a plurality of said welders to a network interface to establish a network connection between said plurality of welders.

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

73. The method as defined in claim 57, wherein said step of obtaining energy consumption information from a plurality of said welders includes exchange information between a plurality of said welders and the remote system.

74. The method as defined in claim 58, wherein said step of obtaining energy consumption information from a plurality of said welders includes exchange information between a plurality of said welders and the remote system.

75. The method as defined in claim 59, wherein said step of obtaining energy consumption information from a plurality of said welders includes exchange information between a plurality of said welders and the remote system.

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

77. The method as defined in claim 57, including the step of monitoring at least one welding function of a plurality of welders and coordinating, controlling or combinations thereof a plurality of said welders based at least partially on said monitored welding functions.

78. The method as defined in claim 58, including the step of monitoring at least one welding function of a plurality of welders and coordinating, controlling or combinations thereof a plurality of said welders based at least partially on said monitored welding functions.

79. The method as defined in claim 59, including the step of monitoring at least one welding function of a plurality of welders and coordinating, controlling or combinations thereof a plurality of said welders based at least partially on said monitored welding functions.

80. The method as defined in claim 76, including the step of monitoring at least one welding function of a plurality of welders and coordinating, controlling or combinations thereof a plurality of said welders based at least partially on said monitored welding functions.

81. 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 at least one of said 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 controlling creating an operating signal to cause termination of at least one of said welders when said totalized energy consumption equals or exceeds said reference value.