System and method for cavity-backed antenna

A system includes a housing, a radio module, and an antenna coupled to the radio module. The housing includes a first wall having one or more openings, and the housing defines a cavity. The radio module and the antenna are disposed at least partially within the cavity of the housing. The radio module is configured to transmit or to receive a radio signal in a desired frequency spectrum via the antenna. The one or more openings are configured to contribute to the housing having a resonant frequency within the desired frequency spectrum.

BACKGROUND

The invention relates generally to wireless communications and, more particularly, to systems and methods for wireless communications in a welding system.

Welding is a process that has increasingly become utilized in various industries and applications. Such processes may be automated in certain contexts, although a large number of applications continue to exist for manual welding operations. In both cases, such welding operations rely on communication between a variety of types of equipment (e.g., devices) to ensure that welding operations are performed properly.

Certain welding systems may include devices that communicate with each other using wired communication, while other welding systems may include devices that communicate with each other using wireless communication. A wireless communication system utilizes a radio module coupled to an antenna to receive or transmit electromagnetic waves for wireless communication. Unfortunately, some antennas (e.g., whip antenna, dipole, rubber ducky antenna) tuned for wavelengths used for wireless communications within or among welding systems may be relatively large, bulky, or obtrusive. Additionally, regulations on wireless transmissions may specify various characteristics of wireless communications systems to reduce electromagnetic interference, which may increase design costs for yet unapproved antennas.

BRIEF DESCRIPTION

In one embodiment, a system includes a housing, a radio module, and an antenna coupled to the radio module. The housing includes a first wall having one or more openings, and the housing defines a cavity. The radio module and the antenna are disposed at least partially within the cavity of the housing. The radio module is configured to transmit or to receive a radio signal in a desired frequency spectrum via the antenna. The one or more openings are configured to contribute to the housing having a resonant frequency within the desired frequency spectrum.

In another embodiment, a welding system includes a wireless communications circuitry component and a welding device. The welding device includes an enclosure and a housing disposed at least partially within the enclosure. The housing includes one or more openings, a radio module at least partially disposed within the housing, and an antenna coupled to the radio module and disposed at least partially within the housing. The radio module is configured to communicate wirelessly with the wireless communications circuitry component with a radio signal in a desired frequency spectrum via the antenna. The housing is resonant at a frequency within the desired frequency spectrum, and a configuration of the one or more openings is configured to increase a gain of the radio signal within the desired frequency spectrum.

In another embodiment, a method includes disposing an antenna at least partially within a housing, disposing a radio module at least partially within the housing, and coupling the radio module to the antenna. The radio module is configured to control the antenna to transmit a radio signal in a desired frequency spectrum, and the housing is resonant with the radio signal in the desired frequency spectrum.

DETAILED DESCRIPTION

Turning to the figures,FIG. 1illustrates an embodiment of a welding system10(e.g., a gas metal arc welding (GMAW) system) where a welding power unit12and one or more welding devices14may be utilized together in accordance with aspects of the present disclosure. It should be appreciated that, while the present discussion may focus specifically on the GMAW system10illustrated inFIG. 1, the presently disclosed communication methods may be used in systems using any type of arc welding process (e.g., FCAW, FCAW-G, GTAW (i.e., TIG), SAW, SMAW, or similar arc welding process). Furthermore, although the present disclosure specifically relates to communications among welding devices, the communications methods provided herein may be applied to any two devices utilized together.

As illustrated, the welding system10includes the welding power unit12, the welding device14(e.g., a welding wire feeder, remote device, pendant, remote control), a gas supply system16, and a welding torch18. In some embodiments, the welding device14is a welding helmet. The welding power unit12generally supplies welding power (e.g., electrical power at a voltage, current, and so forth, suitable for use in a welding process) to the welding system10, and the welding power unit12may be coupled to the welding device14via a cable bundle20as well as coupled to a workpiece22using a work cable24having a clamp26. The work cable24may be integrated with or separate from the cable bundle20.

In some embodiments, the cable bundle20includes a wired communication line between the welding power unit12and the welding device14. For example, in certain embodiments, the welding power unit12may communicate with the welding device14via power line communication where data is provided (e.g., transmitted, sent, transferred, delivered) over welding power (e.g., over the same physical electrical conductor). As will be appreciated, the welding power unit12may communicate (e.g., receive and/or transmit signals) with the welding device14using any suitable wired or wireless protocol (e.g., RS-232, RS-485, Ethernet, a proprietary communication protocol). In certain embodiments, the welding power unit12and the welding device14may communicate using a wired communication line that links the welding power unit12and the welding device14via a network (e.g., Internet, intranet). For example, both the welding power unit12and the welding device14may be wired to the Internet using an Ethernet cable. Accordingly, the welding power unit12may communicate with the welding device14via the Internet. In some embodiments, the welding power unit12and the welding device14may communicate (e.g., either directly or indirectly via a network) using a wireless radio signal (e.g., Wi-Fi, Bluetooth, Zigbee, cellular). For example, a cellular radio signal may communicate via standards including, but not limited to, the Code Division Multiple Access (CDMA) standard, the Global System for Mobile Communications (GSM) standard, or any combination thereof.

The welding power unit12may generally include power conversion circuitry28that receives input power from a power source30(e.g., an AC power grid, an engine/generator set, or a combination thereof), conditions the input power, and provides DC or AC output power via the cable bundle20. As such, the welding power unit12may power the welding device14that, in turn, powers the welding torch18, in accordance with demands of the welding system10. The work cable24terminating in the clamp26couples the welding power unit12to the workpiece22to close the circuit between the welding power unit12, the workpiece22, and the welding torch18. The power conversion circuitry28may include circuit elements (e.g., transformers, rectifiers, switches, boost converters, buck converters, and so forth) capable of converting the AC input power to a direct current electrode positive (DCEP) output, direct current electrode negative (DCEN) output, DC variable polarity, pulsed DC, or a variable balance (e.g., balanced or unbalanced) AC output, as dictated by the demands of the welding system10.

The illustrated welding system10includes the gas supply system16that supplies a shielding gas or shielding gas mixtures from one or more shielding gas sources32to the welding torch18. The gas supply system16may be directly coupled to the welding power unit12, the welding device14, and/or the torch18via a gas conduit34. A gas control system36having one or more valves respectively coupled to the one or more shielding gas sources32may regulate the flow of gas from the gas supply system16to the welding torch18. The gas control system36may be integrated with the welding power unit12, the welding device14, or the gas supply system16, or any combination thereof.

A shielding gas, as used herein, may refer to any gas or mixture of gases that may be provided to the arc and/or weld pool in order to provide a particular local atmosphere (e.g., to shield the arc, improve arc stability, limit the formation of metal oxides, improve wetting of the metal surfaces, alter the chemistry of the weld deposit relative to the filler metal and/or base metal, and so forth). In general, the shielding gas is provided at the time of welding, and may be turned on immediately preceding the weld and/or for a short time following the weld. In certain embodiments, the shielding gas flow may be a shielding gas or shielding gas mixture (e.g., argon (Ar), helium (He), carbon dioxide (CO2), oxygen (O2), nitrogen (N2), similar suitable shielding gases, or any mixtures thereof). For example, a shielding gas flow (e.g., delivered via conduit34) may include Ar, Ar/CO2mixtures, Ar/CO2/O2mixtures, Ar/He mixtures, and so forth.

In the illustrated embodiment, the welding device14is coupled to the welding torch18via a cable bundle38in order to supply consumables (e.g., shielding gas, welding wire) and welding power to the welding torch18during operation of the welding system10. In another embodiment, the cable bundle38may only provide welding power to the welding torch18. During operation, the welding torch18may be brought near the workpiece22so that an arc40may be formed between the consumable welding electrode (i.e., the welding wire exiting a contact tip of the welding torch18) and the workpiece22.

The welding system10is designed to allow for data settings (e.g., weld parameters, weld process) to be selected or input by the operator, particularly via an operator interface42provided on the welding power unit12. The operator interface will typically be incorporated into a front faceplate of the welding power unit12, and may allow for selection of settings. The selected settings are communicated to control circuitry44within the welding power unit12. The control circuitry44, described in greater detail below, operates to control generation of welding power output from the welding power unit12that is applied to the welding wire by the power conversion circuitry28for carrying out the desired welding operation. The control circuitry44may control the power conversion circuitry28based at least in part on data settings received via the operator interface42, data settings received via communications circuitry46of the welding power unit12, or any combination thereof. As discussed in detail below, the data settings received via the communications circuitry46may be received via a wired and/or wireless connection with one or more networked devices, such as another welding power unit12, welding device14, gas supply system16, torch18, a sensor, a work station, a server, and so forth, or any combination thereof. As discussed in detail below, the welding system10may include multiple communications circuitry modules46within the welding power unit12, the one or more welding devices14, the gas supply system16, the torch18, or any combination thereof. The communications circuitry modules46of components of the welding system10may be communicatively coupled (i.e., paired, networked) with one another over one or more of a variety of communication channels including, but not limited to, power line communication, RS-232, RS-485, Ethernet, Wi-Fi, WiMAX, Zigbee, Bluetooth, another Institute of Electrical and Electronics Engineers (IEEE) standard (e.g., 802.11, 802.15), cellular (e.g., cellular digital packet data), high speed circuit switched data, multichannel multipoint distribution service, local multipoint distribution service, or any combination thereof. In some embodiments, the communications circuitry modules46and operator interfaces42may enable data settings (e.g., wire feed speeds, weld processes, currents, voltages, arc lengths, power levels) to be set on one or more components of the welding system10, such as the welding power unit12, the one or more welding devices14, the gas supply system16, the torch18, or any combination thereof. Additionally, or in the alternative, data settings stored in a memory and/or a database may be transmitted to the communications circuitry46from a computer, a workstation, a server, or any combination thereof.

Device control circuitry48of the one or more welding devices14may control various components of the respective welding device14. In some embodiments, the device control circuitry48may receive input from an operator interface42of the welding device14and/or input from the communications circuitry46of the welding device14. In some embodiments, the one or more welding devices14may include a wire feeder having a wire feed assembly50controlled by the device control circuitry48. The wire feed assembly50may include, but is not limited to, a motor, drive wheels, a spool, or power conversion circuitry, or any combination thereof. The device control circuitry48may control the feed of welding wire from the spool to the torch18in accordance with input received via the operator interface42or the communications circuitry46for a desired welding application. In some embodiments, the operator interface42of the welding device14may enable the operator to select one or more weld parameters, such as wire feed speed, the type of wire utilized, the current, the voltage, the power settings, and so forth.

During a welding application, power from the welding power unit12is applied to an electrode52(e.g., wire), typically by means of a weld cable54of the cable bundle38coupled to the torch18. Similarly, shielding gas via the gas conduit34may be fed through the cable bundle38to the torch18. In some embodiments, the wire42is advanced through the cable bundle38towards the torch18during welding operations. When a trigger switch56on the torch18is actuated, communications circuitry46in the torch18may be configured to provide a signal (e.g., wired or wireless) to the welding power unit12, the welding device14, or the gas supply system16, or any combination thereof, thereby enabling the welding process to be started and stopped by the operator. That is, upon depression of the trigger switch56, gas flow is begun, a wire may be advanced, and power is applied to the weld cable54and through the torch16for the welding application. In some embodiments, the communications circuitry46in the torch18may facilitate communication between the torch18and other components of the welding system10during the welding application.

Components of the welding power unit12, the welding device14, and the gas supply system16may be disposed at least partially within respective enclosures. For example, the control circuitry44, power conversion circuitry28, communications circuitry46, and the gas control36of the welding power unit12are arranged within a first enclosure58. The operator interface42may be integrated with and/or mounted to the first enclosure58. In a similar manner, a second enclosure60may at least partially enclose components of the welding device14, such as the gas control36, the operator interface42, the communications circuitry46, the welding device control circuitry48, and the wire feed assembly50. A third enclosure62may at least partially enclose components of the gas supply system16, such as the shielding gas sources32, the gas control36, and communications circuitry46. As may be appreciated, the enclosures58,60,62may partially enclose or substantially fully enclose components of the respective systems. For example, the enclosures may have access ports and/or panels to facilitate operator access to components (e.g., controls, connectors, I/O ports) disposed within the enclosure. Walls of the enclosures may provide at least some environmental protection for the components disposed therein. Additionally, or in the alternative, the enclosures may include one or more openings for ventilation and/or drainage.

In some embodiments, a housing64of the communications circuitry46may be at least partially integrated with an enclosure of the welding system10. For example, an emission face66(e.g., a face from which wireless signals70are emitted) of the housing64may be a portion of an external face68of the first enclosure58about the welding power unit12. In some embodiments, the housing64may be mounted in a recess of an enclosure (e.g., first enclosure58) such that the emission face is substantially flush with an external face of the enclosure. The emission face66is a conformal antenna (e.g., slot antenna) that emits or receives radio signals via designed openings74, as discussed in detail below. In some embodiments, the housing64is resonant with radio signals within a desired frequency spectrum that is utilized by an antenna72. The resonance of the housing64with the radio signals in a desired frequency spectrum transmitted by the antenna72enables the communications circuitry46to efficiently transmit the radio signals via the emission face66of the housing64, thereby reducing the profile and bulk of the communications circuit46without significantly affecting the power of the radio signals transmitted with other communications circuits46within the welding system10. As discussed in detail below, various features of the housing64and the emission face66may affect the gain and/or directionality of a wireless signal70emitted from the housing64. The various features that may affect the wireless signal70may include, but are not limited to, the shape of the housing64(e.g., curved, angular, rectangular, etc.), the geometry of the housing64(e.g., length, width, height, cavity volume, etc.), whether the cavity is fully enclosed except for the one or more designed openings74, the position of the antenna72within the housing64, the materials of the housing64, the materials of the antenna72, a dielectric medium within the housing64, and the configuration of one or more designed openings74of the emission face66of the housing64, or any combination thereof. The housing64at least partially encompasses the antenna72, thereby forming a cavity-backed antenna.

FIG. 2illustrates an assembly view of an embodiment of a cavity-backed antenna system80of the communications circuitry46. The communications circuitry46of the welding power unit12, the welding device14, the gas supply system16, and/or the torch18may include an embodiment of the cavity-backed antenna system80as described in detail below. The cavity-backed antenna system80includes the housing64, the antenna72, and a radio module82. The radio module82is coupled to the antenna72, and the radio module82is disposed at least partially within the housing64with the antenna72. The antenna72may be separate from or integrally formed with the radio module82. That is, where the radio module82is disposed on a printed circuit board, the antenna72may be a printed element of the printed circuit board. In some embodiments, the antenna72is a monopole antenna. The radio module82may include, but is not limited to, processing circuitry (e.g., wireless transmitter) configured to transmit information via one or more radio signals in a desired frequency spectrum (e.g., 100 MHz to 20 GHz, 300 MHz to 10 GHz, 800 MHz to 5 GHz, 1 GHz to 2.5 GHz), processing circuitry (e.g., wireless receiver) configured to receive information via one or more radio signals, or any combination thereof (e.g., wireless transceiver). In some embodiments, the antenna72is integrated with the radio module82.

The housing64is configured to at least partially encompass the radio module82and the antenna72. In some embodiments, the housing64fully encloses the antenna72. The housing64may have multiple components, such as a base84, walls86, and the emission face66. In some embodiments, the emission face66is one of the walls86. In some embodiments, one or more components of the housing64may be integrated with one another and/or formed together. For example, the housing64may be formed (e.g., folded) from a sheet of a housing material including, but not limited to, aluminum, copper, steel (e.g., stainless steel), metalicized plastic, or any combination thereof. In some embodiments, the housing64may have one or more layers of aluminum, copper, steel (e.g., stainless steel), plastic, a quartz material, a printed circuit board, a flexible printed circuit board, or any combination thereof. In some embodiments, the housing64may have an electrically conductive inner face88, thereby electrically coupling the radio module82to the housing64. For example, the radio module82may be electrically coupled to the emission face66, thereby enabling the emission face66with the designed openings74to directly receive or transmit the radio signals with the radio module82. Additionally or in the alternative, the electrically conductive emission face66passively re-emits radio signals received from the antenna72or from the communications circuitry46of other components of the welding system10.

In some embodiments, the housing64may shield the antenna72from external electromagnetic interference. For example, the housing64may have one or more layers of different materials to shield the radio module82and the antenna72from high frequency and low frequency electromagnetic interference. Shielding by the housing64may enable the antenna72to be coupled to the radio module82via an unshielded electrical connection. Additionally, or in the alternative, one or more walls86may be coupled to the base84and/or the emission face66via a fastener, an adhesive, a weld, a braze, an interference fit, or any combination thereof. In some embodiments, the emission face66may be a wall86of the housing64such that the emission face66couples to the base84. Moreover, whileFIG. 2illustrates the housing64about the radio module82and the antenna72as having a rectangular shape, a cross-sectional shape of the housing64may include, but is not limited to a cylinder, a sphere, a dome, a horn, or a triangular prism.

The geometry of the housing64may be configured to be resonant with the one or more radio signals, to affect the gain of the one or more radio signals, and/or to affect the directionality of the one or more radio signals emitted from the antenna72. A length90, a width92, and a height94of the housing64may be designed to be resonant for a desired frequency range about a target frequency of radio signals utilized by the antenna72. The power for generating radio signals is utilized more efficiently at frequencies that are resonant with an antenna, thereby reducing energy losses (e.g., heat). In a similar manner, the emission face66and openings74of the housing64re-emits radio signals from the antenna72or other communications circuits46more efficiently at frequencies that are resonant with the housing64than at frequencies that are not resonant with the housing64. That is, the cavity-backed antenna system80may emit radio signals at resonant frequencies of the antenna72and/or the housing64more efficiently than radio signals emitted at non-resonant frequencies. The antenna72transfers energy to the emission face66and the openings74via the emitted radio signals, and the emission face66re-emits the radio signals. Accordingly, the geometry of the housing64is designed to be resonant for a desired frequency range about a target frequency emitted by the antenna72, thereby increasing the efficiency of the cavity-backed antenna system80. Moreover, the one or more openings74may be designed to be designed as an antenna (e.g., slot antenna) that is resonant for a desired frequency range about a target frequency emitted by the antenna72. For example, the one or more openings74may be one or more slot antennas having lengths that approximate the lengths of resonant dipole antennas for the desired frequency range about the target frequency.

The walls86and the emission face66define a cavity96within the housing64. In some embodiments, walls86, the emission face66, and the base84substantially fully enclose the cavity96, except for the one or more openings74and one or more ports120. In some embodiments, the cavity96is not substantially fully enclosed, such as if portions of the one or more of the walls86or the base86is removed from the embodiment illustrated inFIG. 2. The antenna72and the radio module82may be disposed substantially entirely within the cavity96, such as by mounting the radio module82to the base84within the cavity96. In some embodiments, the radio module82extends at least partially through an iris of the base84or the walls86into the cavity96. Additionally, or in the alternative, the antenna72may extend at least partially through the base84or the walls86into the cavity96. In some embodiments, a dielectric medium98may be arranged within the cavity96. The dielectric medium98may include, but is not limited to, a plastic, a foam, a resin, air, an inert gas, or any combination thereof. In some embodiments, the dielectric medium98may be utilized to maintain the antenna72and/or the radio module82at a desired resonant position within the housing64. For example, the antenna72and/or the radio module82may be coupled with the dielectric medium98. Additionally, or in the alternative, the dielectric medium98may have a complementary geometry (e.g., negative image) of the antenna72and the radio module82. The complementary geometry of the dielectric medium98may mate with (e.g., abut) or be spaced a distance from the antenna72or the radio module82when the cavity-backed antenna system80is assembled. The dielectric medium98may insulate and protect the antenna72and/or the radio module82from external shocks and vibrations to the cavity-backed antenna system80.

The antenna72is arranged within the enclosure64to enable the one or more designed openings74of the emission face66to affect the one or more emitted or received radio signals. For example, the antenna72may be arranged within the enclosure64to maintain a first spacing100from the base84, a second spacing102from a first wall104, and a third spacing106from a third wall108. The one or more designed openings74of the emission face66may include, but are not limited to, a slot110, a hole112, a coil, or any combination thereof. The geometry of the one or more designed openings74may affect the resonant frequency, the gain, and/or the directionality of the radio signals emitted from or received by the cavity-backed antenna system80. In some embodiments, the slots110are approximately rectilinear slots110. Additionally, or in the alternative, the slots110have a zig-zag shape. Additionally, or in the alternative, spacing of the one or more designed openings74across the emission face66may affect the resonant frequency, the gain, and/or the directionality of the cavity-backed antenna system80. For example, a width114and a length116of one or more slots110may be tuned for a resonant frequency (e.g., 2.45 GHz) that is a target frequency utilized to communicate with the communications circuits46of other components of the welding system10.

Antennas transmit radio signals at the resonant frequency of the antenna with a greater efficiency than radio signals at non-resonant frequencies. The resonant frequency of an antenna system is related to the electrical length of the antenna system, where the impedance of the antenna system at the resonant frequency approximates a pure resistance (e.g., no reactance) to the signal source, such as the radio module82. A dipole antenna without any added inductance or capacitance may have a physical length and an electrical length approximately equal to half of the wavelength of the resonant frequency, and a monopole antenna may have a physical length and an electrical length approximately equal to one quarter of the wavelength of the resonant frequency. By adding inductance to the cavity-backed antenna system80, the electrical length of the cavity-backed antenna system80may be increased without increasing the physical length, thereby increasing the resonant frequency of the cavity-backed antenna system80for a given physical length. Some embodiments of the cavity-backed antenna system80are configured to increase the electrical length of the cavity-backed antenna system80such that the cavity-backed antenna system80is resonant for a frequency range that includes the target frequency (e.g., 2.45 GHz) utilized to communicate with the communications circuits46of other components of the welding system10. The electrical length of the cavity-backed antenna system80may be increased without increasing the bulk (e.g., footprint) of the communications circuitry46. Moreover, increasing the electrical length of the cavity-backed antenna system80may enable the bulk of the communications circuitry46to be decreased. Accordingly, the cavity-backed antenna system80may streamline a profile of the communications circuitry46by disposing the antenna72within the housing64, such that the emission face66of the housing64re-emits the radio signals as a conformal antenna (e.g., slot antenna). The housing64may protect the antenna72from external shocks or from being snagged.

The one or more resonant frequencies of the housing64of the cavity-backed antenna system64are affected by the shape of the housing64, the geometry (e.g., length92, width94, height94) of the housing64, the position of the antenna72within the housing64, the materials of the housing64, the dielectric medium98, the quantity of designed openings74, the configuration of the one or more designed openings74, the geometry of the one or more designed openings74, or any combination thereof. Furthermore, the dielectric medium98disposed within the housing64about the antenna72may also electrically lengthen cavity-backed antenna system80, thereby enabling the designed openings74to be shorter and/or the housing64to be smaller without changing the resonant frequency of the cavity backed antenna system80. For example, increasing the dielectric constant of the dielectric medium98disposed within the housing64may enable the volume of the housing64to decrease without affecting the resonant frequency of the cavity-backed antenna system80. Additionally, or in the alternative, the dielectric medium98enables the width114and/or the length116of the designed openings74to be shortened without otherwise affecting the resonant frequency. Accordingly, the housing64and the dielectric medium98may reduce the bulk of the communications circuitry46that may be utilized with the power supply unit12, the welding device14, the gas supply system16, the torch18, or any combination thereof.

The disposition of the radio module82within the housing64of the cavity-backed antenna system80reduces the bulk and footprint of the communications circuitry46. For example, the disposition of the radio module82within the housing64reduces the quantity of components of the communications circuitry46that are to be installed within a component (e.g., the power supply unit12, the welding device14, the gas supply system16, the torch18, etc.) of the welding system10. That is, the communications circuitry46may be the cavity-backed antenna system80with the integrated antenna72and radio module82disposed within, rather than a separate radio module that is external to the antenna and the housing64. In some embodiments, the cavity-backed antenna system80may be a modular component that may be utilized as the communications circuitry46within the welding power unit12, the welding device14, the gas supply system16, the torch18, or any combination thereof.

The radio module82within the housing64may be coupled to one or more cables118. The one or more cables118may supply power to the radio module82. Additionally, or in the alternative, the one or more cables118may couple the radio module82to an operator interface42or control circuitry (e.g., the control circuitry44, the gas control system36, the device control circuitry48, etc.). The one or more cables118may be coupled to the radio module82through a port120in the base84, a wall86, or the emission face66. In some embodiments, the dielectric medium98may have one or more recesses122to accommodate the one or more cables118coupled to the radio module82.

The emission face66of the housing64may be integrated with the walls86or separately coupled to the walls86and the base84. In some embodiments, an open face124of the housing64may interface with the emission face66. The emission face66may extend beyond the walls86of the housing64, such as when the emission face66is an external face68of an enclosure. In some embodiments, the housing64with the emission face66is disposed within an enclosure (e.g., first enclosure58, second enclosure60, etc.).

FIG. 3illustrates a cross-sectional view of an embodiment of the cavity-backed antenna system80. As discussed above, the radio module82and the antenna72are disposed within the housing64. The dielectric medium98may at least partially fill the cavity96between the base84, the walls86, and the emission face66of the housing64. In some embodiments, the dielectric medium98may interface (e.g., directly contact) with portions of the antenna72and/or the radio module82. For example, the dielectric medium98may maintain the position of the antenna72in a resonant position (e.g., spacing from the walls86and designed opening74) within the housing64. In some embodiments, the dielectric medium98may be spaced apart from (i.e., not directly abutting) the antenna72and/or the radio module82.

One or more designed openings74of the emission face66facilitate the transmission of radio signals from cavity-backed antenna system80at frequencies within the desired frequency spectrum. The one or more designed openings74of the emission face66receive the transmitted radio signals from the antenna72, and re-radiate the received radio signals at the target frequency to communicate with other communications circuits46of the welding system10. In some embodiments, one or more layers140may be disposed over at least a portion of the one or more desired openings74to affect the transmission of the radio signals from the cavity-backed antenna system80. For example, the one or more layers140may include a first layer142(e.g., foil, printed circuit elements) with one or more patterned portions144(e.g., radiating elements). The one or more patterned portions144may be electrically conductive and tuned to affect the gain of the transmitted radio signal within the desired frequency spectrum (e.g., 100 MHz to 20 GHz, 300 MHz to 10 GHz, 800 MHz to 5 GHz, 1 GHz to 2.5 GHz). The one or more layers140may include a second layer146(e.g., backing layer). For example, the one or more layers140may be a printed circuit board in which the first layer142includes electrically conductive printed patterned portions144to be disposed at across one or more of the designed openings74, and the second layer146may be a substrate for the first layer142. In some embodiments, the one or more layers140may include a label or decal, thereby enabling the one or more layers140to interface (e.g., adhere) with the emission face66and/or the housing64. Accordingly, the one or more layers140may at least partially extend over the one or more designed openings74, thereby at least partially obscuring the one or more designed openings74from view.

FIG. 4illustrates a top view of the cavity-backed antenna system80, taken along line4-4ofFIG. 3. The patterned portion144extends at least partially across one or more designed openings74of the emission face66. The patterned portion144may include a radiating element148. In some embodiments, the patterned portion144may be stamped or cut in the one or more layers140. Additionally, or in the alternative, the patterned portion144may be printed on a substrate. For example, the patterned portion144may include copper, aluminum, or silver features disposed on a printed circuit board (PCB) substrate. A cable150coupled to the radiating element148of the patterned portion144may supply a signal that enables the radiating element148to transmit a radio signal. The radiating element148may be utilized separately from or with the antenna72to transmit one or more radio signals. In some embodiments, the radiating element148augments the signal strength or directionality of the radio signals transmitted by the antenna72disposed within the cavity96.