ENGINE DRIVEN WELDING-TYPE POWER SUPPLIES WITH REFUELING DETECTION SYSTEMS

Described herein are examples of welding-type power supplies with refueling detection systems that use provide user perceptible outputs from refueling output devices proximate the fuel tank (and/or fuel tank inlet), so that the output can be perceived by the operator when refueling. The outputs may indicate how much fuel is in the fuel tank, and/or whether the fuel tank has been filled to capacity, so the operator knows when to stop refueling. The refueling detection system is additionally configured to operate even when the power supply is turned off, in case the power supply is turned off prior to refueling (as is the best practice).

TECHNICAL FIELD

The present disclosure generally relates to welding-type power supplies, and more particularly to engine driven welding-type power supplies with refueling detection systems.

BACKGROUND

Some welding-type power supplies use engines to generate electrical power for welding-type operations. As the engines require a constant supply of fuel to operate, some engine driven welding-type power supplies also include fuel tanks that hold fuel for use by the engines. When the fuel in the fuel tank is depleted, the fuel tank must be refilled.

SUMMARY

The present disclosure is directed to engine driven welding-type power supplies with refueling detection systems, for example, substantially as illustrated by and/or described in connection with at least one of the figures, and as set forth more completely in the claims.

These and other advantages, aspects and novel features of the present disclosure, as well as details of an illustrated example thereof, will be more fully understood from the following description and drawings.

The figures are not necessarily to scale. Where appropriate, similar or identical reference numerals are used to refer to similar or identical components. For example, reference numerals utilizing lettering (e.g., controllable circuit element402a,controllable circuit element402b) refer to instances of the same reference numeral that does not have the lettering (e.g., controllable circuit elements402).

DETAILED DESCRIPTION

While some existing engine driven welding-type power supplies have fuel gauges on the front panel of the power supply, the fuel tank itself (and the fuel tank inlet) is often positioned closer to the rear and/or side of the power supply. Thus, an operator is often positioned to the side or rear of the power supply when refueling the fuel tank. In such a position the front panel fuel gauge is not easily visible. Lack of visibility may result in under filling or over filling the fuel tank, either of which may cause problems (e.g., spillage, running problems, etc.). Additionally, best practice for power supply refueling involves turning off the power supply for refueling, which results in the front panel fuel gauge (and/or associated sensors) being turned off as well. As the front panel fuel gauge will likely be off when refueling, even if the operator could see the fuel gauge on the front panel of the power supply when refueling, the fuel gauge would be inoperative and unhelpful.

Some examples of the present disclosure relate to refueling detection systems having output devices positioned proximate the fuel tank inlet that receive power even when the power supply is turned off. In some examples, a refueling detection system may use one or more refueling sensors to detect when a fuel tank is being refueled, and/or determine the volume (and/or level) of fuel in the fuel tank. The refueling detection system may use one or more of the output devices positioned proximate the fuel tank to provide an indication of the fuel level to the operator, so that the operator can be aware of how full the fuel tank is, and/or when/whether the fuel tank has been filled to capacity.

Some examples of the present disclosure relate to an engine driven power supply, comprising: a fuel tank configured to store a volume of fuel; an engine-generator configured to use the fuel stored in the fuel tank to generate electrical power; an energy storage device configured to output stored power; a refueling detection system that receives the stored power from the energy storage device even when the engine driven power supply is powered off, the powered off refueling detection system comprising: a fuel level sensor configured to detect fuel level sensor data indicative of the volume of the fuel within the fuel tank, control circuitry configured to receive the fuel level sensor data from the fuel level sensor, and determine the volume of the fuel in the fuel tank based on the fuel level sensor data, and an output device configured to provide a perceptible output indicative of the volume of the fuel in the fuel tank.

In some examples, the fuel level sensor is configured to operate in a lower power mode, where the fuel level sensor data is detected at a lower sampling rate, and the fuel level sensor is configured to switch to operation in a higher power mode, where the fuel level sensor data is detected at a higher sampling rate, in response to being activated by the control circuitry. In some examples, the control circuitry is configured to activate the fuel level sensor in response to determining, based on the fuel level sensor data, that that fuel tank is being refueled. In some examples, the refueling detection system further comprises a refueling sensor configured to detect when the fuel tank is being refueled, the control circuitry being configured to activate the fuel level sensor in response to the refueling sensor detecting the fuel tank is being refueled.

In some examples, the fuel level sensor is configured to return to operation in the lower power mode a threshold time period after the control circuitry determines that (i) the fuel tank is no longer being refueled, or (ii) the volume of the fuel within the fuel tank has reached a threshold level. In some examples, (i) the fuel level sensor comprises an optical sensor, a float sensor, a moisture sensor, an acoustic sensor, a depth sensor, a distance sensor, weight sensor, or a proximity sensor, (ii) the fuel level sensor is positioned in or on a neck of the fuel tank, or (iii) the output device is configured to provide the perceptible output in response to the volume of the fuel in the fuel tank reaching a threshold level. In some examples, the output device comprises a first output device, the engine driven power supply further comprising a second output device comprising an electrical fuel gauge, the second output device receiving stored power from the energy storage device only when the engine driven power supply is powered on.

In some examples, the engine driven welding power supply further comprises a housing enclosing the power conversion circuitry and the energy storage device, the housing comprising a front panel, a rear panel, and a side panel connecting the front and rear panel, the second output device being positioned on or in the front panel of the housing, and the first output device not being positioned on or in the front panel of the housing. In some examples, the second output device is part of a circuit that comprises the second output device, the energy storage device, and a power switch. In some examples, the engine driven welding power supply further comprises a power switch interface configured to receive user input, and open or close the power switch in response to the user input, wherein the circuit is complete, and the second output device is powered by the stored power, when the power switch is closed, and the circuit is broken, and the second output device is unpowered, when the power switch is open.

Some examples of the present disclosure relate to an engine driven welding-type power supply, comprising: a fuel tank configured to store a volume of fuel; an engine-generator configured to use the fuel stored in the fuel tank to generate electrical power; power conversion circuitry configured to receive the electrical power from the generator as input power and convert the input power to welding-type output power based on one or more control signals; an energy storage device configured to output stored power; a refueling detection system that receives the stored power from the energy storage device even when the engine driven power supply is powered off, the powered off refueling detection system comprising: a fuel level sensor configured to detect fuel level sensor data indicative of the volume of the fuel within the fuel tank, control circuitry configured to receive the fuel level sensor data from the fuel level sensor, and determine the volume of the fuel in the fuel tank based on the fuel level sensor data, and an output device configured to provide a perceptible output indicative of the volume of the fuel in the fuel tank.

In some examples, the fuel level sensor is configured to operate in a lower power mode, where the fuel level sensor data is detected at a lower sampling rate, and the fuel level sensor is configured to switch to operation in a higher power mode, where the fuel level sensor data is detected at a higher sampling rate, in response to being activated by the control circuitry. In some examples, the control circuitry is configured to activate the fuel level sensor in response to determining, based on the fuel level sensor data, that that fuel tank is being refueled. In some examples, the refueling detection system further comprises a refueling sensor configured to detect when the fuel tank is being refueled, the control circuitry being configured to activate the fuel level sensor in response to the refueling sensor detecting the fuel tank is being refueled.

In some examples, the fuel level sensor is configured to return to operation in the lower power mode a threshold time period after the control circuitry determines that (i) the fuel tank is no longer being refueled, or (ii) the volume of the fuel within the fuel tank has reached a threshold level. In some examples, (i) the fuel level sensor comprises an optical sensor, a float sensor, a moisture sensor, an acoustic sensor, a depth sensor, a distance sensor, weight sensor, or a proximity sensor, (ii) the fuel level sensor is positioned in or on a neck of the fuel tank, or (iii) the output device is configured to provide the perceptible output in response to the volume of the fuel in the fuel tank reaching a threshold level. In some examples, the output device comprises a first output device, the engine driven power supply further comprising a second output device comprising an electrical fuel gauge, the second output device receiving stored power from the energy storage device only when the engine driven power supply is powered on.

In some examples, the engine driven welding power supply further comprises an electrical socket and a housing, the electrical socket being in electrical communication with the power conversion circuitry and configured for connection with an electrical cable that will route the output power to a welding-type tool or welding-type equipment, the housing enclosing the power conversion circuitry and the energy storage device, the housing comprising a front panel, a rear panel, and a side panel connecting the front and rear panel, the electrical socket and the second output device being positioned on or in the front panel of the housing, and the first output device not being positioned on or in the front panel of the housing. In some examples, the second output device is part of a circuit that comprises the second output device, the energy storage device, and a power switch. In some examples, the engine driven welding power supply further comprises a power switch interface configured to receive user input, and open or close the power switch in response to the user input, wherein the circuit is complete, and the second output device is powered by the stored power, when the power switch is closed, and the circuit is broken, and the second output device is unpowered, when the power switch is open.

FIG.1shows an example engine-driven welding-type system100. It should be appreciated that, while the example welding-type system100shown inFIG.1may be described as a gas metal arc welding (GMAW) system, the presently disclosed system100may also be used with other arc welding processes (e.g., flux-cored arc welding (FCAW), gas shielded flux-cored arc welding (FCAW-G), gas tungsten arc welding (GTAW), submerged arc welding (SAW), shielded metal arc welding (SMAW), or similar arc welding processes) or other metal fabrication systems, such as plasma cutting systems, induction heating systems, and so forth. In some examples, the disclosure may also be applied outside of welding-type systems.

In the example ofFIG.1, the welding-type system100includes a welding-type power supply102, a wire feeder104, a clamp106, and a tool108. In the example ofFIG.1, the tool108is shown as being a welding-type tool, such as, for example, a welding torch or plasma cutter. In some examples, the tool108may be a different type of tool, such as, for example, an air pump, air compressor, or hydraulic pump.

In the example ofFIG.1, the tool108is connected to the wire feeder104via feeder cable110. In the example ofFIG.1, the wire feeder104houses a wire spool112that is used to provide the tool108with a wire electrode (e.g., solid wire, cored wire, coated wire). In the example ofFIG.1, the wire feeder104further includes rollers114configured to feed the wire electrode to the tool108(e.g., from the spool112) and/or retract the wire electrode from the tool108(e.g., back to the spool112). As shown, the wire feeder104further includes a motor116configured to turn one or more of the rollers114, so as to feed the wire electrode to the tool108via the feeder cable110.

In the example ofFIG.1, the wire feeder104is connected to the welding-type power supply102via power cable118. As shown, the power cable118is connected to a power socket120of the welding-type power supply102via a power plug122at the end of the power cable118. While not specifically labeled, in some examples, the welding wire feeder104may include one or more sockets and/or plugs as well. In some examples, the wire feeder104may route power received from the welding-type power supply102(e.g., via power cable118) to the tool108(e.g., via feeder cable110) along with the wire electrode.

In the example ofFIG.1, the tool108is also shown directly connected to the welding-type power supply102via dotted line124to indicate that, in some examples, the tool108may be directly connected to the power supply102, rather than connected through the wire feeder104. For example, the wire feeder104may be integrated into the power supply102, such that there is no need for the power supply102to connect to the tool108through the wire feeder104. As another example, the wire feeder104may be omitted from the system100entirely.

In the example ofFIG.1, the welding-type power supply102is further coupled to a ground clamp106through ground cable126. The ground clamp106holds a workpiece128that may be worked upon during a welding-type operation. In some examples, the workpiece128and tool108(and/or wire electrode) may form a circuit by way of their electrical connection to the welding-type power supply102. The circuit formed from the workpiece128and tool108(and/or wire electrode) may be open until closed and/or completed by a welding arc. In some examples, a welding arc is formed between the tool108(and/or wire electrode) and the workpiece128using power from the welding-type power supply102when a welding-type process is initiated (e.g., via activation of a trigger of the tool108).

In the example ofFIG.1, the welding-type power supply102includes a housing130. In the example ofFIG.1, the power supply102is shown from a top down perspective, such that the front panel132, rear panel134, and side panels136of the housing130are shown (e.g., with no roof). As shown, many of the components of the welding-type power supply102are enclosed within the housing130. Some of the components of the welding-type power supply102(e.g., sockets120) are shown as extending across the housing130, indicating that the component(s) may be positioned in, on, and/or extending beyond the housing130.

In the example ofFIG.1, the welding-type power supply102supplies power to the tool108, wire electrode, and/or ground clamp106through the sockets120in/on the front panel132of the housing130of the welding-type power supply102. In some examples, the power provided through the sockets120may be welding-type output power. In some examples, the power provided through the sockets120may be auxiliary power (e.g., in addition to welding-type output power.

As shown, the sockets120on the front panel132of the housing130of the welding-type power supply102are electrically connected to power conversion circuitry138of the welding-type power supply102. In some examples, the power conversion circuitry138is configured to convert input power to output power (e.g., welding-type output power, auxiliary output power, and/or other power). In some examples, the power conversion circuitry138may include circuit elements (e.g., transformers, rectifiers, capacitors, inductors, diodes, transistors, switches, and so forth) capable of converting the input power to output power.

In some examples, the power conversion circuitry138may include one or more controllable circuit elements. In some examples, the controllable circuit elements may comprise circuitry configured to change states (e.g., fire, trigger, turn on/off, close/open, etc.) based on one or more control signals. In some examples, the state(s) of the controllable circuit elements may impact the operation of the power conversion circuitry138, and/or impact characteristics (e.g., current/voltage magnitude, frequency, waveform, etc.) of the output power provided by the power conversion circuitry138. In some examples, the controllable circuit elements may comprise, for example, switches, relays, transistors, etc. In examples where the controllable circuit elements204comprise transistors, the transistors may comprise any suitable transistors, such as, for example MOSFETs, JFETs, IGBTs, BJTs, etc.

In the examples ofFIG.2, the welding-type power supply102includes power control circuitry140electrically coupled to the power conversion circuitry138. In some examples, the controllable circuit elements of the power conversion circuitry138may be controlled by (and/or receive control signals from) the power control circuitry140of the welding-type power supply102. In some examples, the power control circuitry140operates to control the power conversion circuitry138, so as to ensure the power conversion circuitry138generates the appropriate output power.

In some examples, the power control circuitry140comprises processing circuitry (e.g., in the form of one or more processor) and/or memory circuitry. In some examples, the processing circuitry may use data stored in the memory circuitry to execute control algorithms to control the power conversion circuitry138. In some examples, the power control circuitry140may control the power conversion circuitry based on weld parameters (e.g., target voltage/current), welding processes, and/or other weld settings input programmatically and/or input by an operator via a user interface (UI)142of the power supply102.

In some examples, the welding-type system100may receive weld settings from the operator via the UI142. In the example ofFIG.1, the UI142is positioned on the front panel132of the housing104, proximate the sockets120. In some examples, the UI142may include one or more input devices and/or output devices. In some examples, input devices may include switches, knobs, levers, buttons, touch screens, microphones, and/or other output devices. In some examples, output devices may include display screens, gauges (e.g., a fuel gauge), speakers, lights, and/or other output devices.

In the example ofFIG.1, the UI142is coupled to the power control circuitry140. In some examples, the UI142may communicate the weld settings/parameters to the power control circuitry140via this coupling. In some examples, the UI142may additionally receive (e.g., sensor) data from the power control circuitry140via the coupling with the power control circuitry140.

In the example ofFIGS.1and2, the welding-type system100includes one or more power supply sensors144connected to the power control circuitry140. In some examples, the power supply sensors144may include one or more sensors configured to detect a volume and/or level of fuel302within a fuel tank300of the power supply (see, e.g.,FIG.3), as discussed below. In some examples, the power supply sensors144may include one or more (e.g., voltage/current) feedback sensors. In some examples, the power control circuitry140may use feedback from the power supply sensor(s)144to control the conversion of input power to output power by the power conversion circuitry138.

In the example ofFIG.1, the power conversion circuitry138receives input power from a generator146of the welding-type power supply102. As shown, the generator146is electrically connected to the power conversion circuitry138. In some examples, the generator146may generate electrical power that may be delivered to the power conversion circuitry138as input power through the electrical connection between the power conversion circuitry138and generator146.

In some examples, the generator146may generate the electrical power (e.g., via a stator of the generator146) from mechanical motion produced by an engine148of the power supply102(e.g., via the rotor of the engine148). In some examples, the engine148may be a combustion engine148. As the engine148and generator146work together to produce the electrical power, in some examples, the term engine-generator may be used as a shorthand to refer collectively to the engine148and generator146.

In some examples, the engine148may be off until started by an engine starter150. In some examples, the engine148may started via the engine starter150using stored energy from an energy storage device152of the power supply102. In some examples, the stored energy from the energy storage device152may be provided to the engine starter150in response to input received from the operator via an on/off interface154of the power supply102.

In some examples, the on/off interface154may include one or more input devices (e.g., switches, knobs, levers, buttons, keys, key ignition barrels, etc.). In some examples, the state(s) (e.g., on/off, open/closed, etc.) of one or more controllable circuit elements402in the on/off circuit400may be changed in response to input received via the on/off interface154. The change in state of the controllable circuit element(s)402in the on/off circuit400may allow or prevent the engine starter150to/from starting the engine148using stored energy from the energy storage device152.

In some examples, the energy storage device152may store and/or output electrical energy and/or power for use by components of the welding-type power supply102. In some examples, the energy storage device152may be a battery, fuel cell, or capacitor. In the example ofFIG.1the energy storage device152is shown electrically connected to the generator146and power conversion circuitry138.

In some examples, the energy storage device152may be recharged by electrical power generated by the generator146and/or power output by the power conversion circuitry138. In some examples, the stored power output by the energy storage device152may be used by the engine starter150to start the engine148. In some examples, the stored power output by the energy storage device152may be used by the engine148(e.g., via spark plugs) to keep the engine148going once started.

In the example ofFIG.1, the engine starter150is shown connected to the engine148and the on/off circuit400. The on/off circuit400is in turn connected to the on/off interface154on the front panel132of the housing130of the power supply102, as well as the energy storage device152of the power supply102. While shown as only connecting to the on/off interface154, engine starter150, and energy storage device152in the example ofFIG.1for the purposes of simplicity and clarity, and to illustrate the impact the on/off interface154and/or on/off circuit400may have on the operation of the engine starter150and/or energy storage device152, in some examples, the on/off circuit400may impact other components of the welding-type power supply102as well (see, e.g.,FIG.4).

Once started, the engine148may use fuel302(e.g., see, e.g.,FIG.3) to produce the mechanical motion of the rotor, through which the generator146generates electrical power. In some examples, the engine148may further include one or more spark plugs to ignite the fuel302from the fuel tank300to keep the engine148going after the engine148has been started. In some examples, the fuel302may be petroleum based, such as, for example, diesel fuel or gasoline.

In the example ofFIG.1, the power supply102includes a fuel tank300is connected to the engine148. In some examples, the fuel302used by the engine148may be stored in the fuel tank300until used. In some examples, the engine148may include a fuel pump to move fuel302from the fuel tank300to the engine148via the connection between the fuel tank300and engine148.

As the fuel tank300is a finite size, the fuel tank300must be periodically refueled. In some examples, one or more of the power supply sensors144may be configured to detect how much fuel302is remaining in the fuel tank300. The UI142in/on the front panel132may further provide an output indicative of the fuel302left in the fuel tank300, so that an operator knows if/when it is time to replenish the supply of fuel302.

However, in the example ofFIG.1, the fuel tank300(and/or the fuel tank inlet304; see, e.g.,FIG.3) is closer to the rear panel134of the housing130than the front panel132. Thus, the operator may need to position themselves closer to the rear panel134of the housing when refueling the fuel tank300. In such a position, the UI142on the front panel132may not be easily visible. Lack of visibility may result in under filling or over filling the fuel tank300, either of which may cause problems (e.g., spillage, running problems, unexpected shutdown, etc.). Additionally, best practices for refueling the power supply102calls for turning off the power supply102(e.g., via the on/off interface154) prior to refueling, which results in the front panel fuel gauge (and/or associated fuel sensors) being turned off as well. Thus, even if the operator could see the fuel gauge on the front panel132of the power supply102, the fuel gauge would likely be inoperative and unhelpful.

To address these issues, the welding-type power supply102shown inFIG.1includes a refueling detection system200. As shown inFIG.1, the refueling detection system200is positioned proximate the fuel tank300(e.g., in or on the rear panel134or side panel136), such that an operator refueling the fuel tank300will be able to perceive (e.g., see, hear, feel, etc.) output of the refueling detection system200indicating a volume and/or level of the fuel302in the fuel tank300. Additionally, the refueling detection system200is configured to operate even when the welding-type power supply102is turned off, so that an operator can be informed of the volume and/or level of the fuel302in the fuel tank300even if the welding-type power supply102is turned off before refueling.

FIG.2is a block diagram showing components of the refueling detection system200. As shown, the refueling detection system200includes a plurality of refueling sensors202, a plurality of refueling output devices204, and refueling control circuitry206. In some examples, one or more of the refueling sensors202may comprise an optical sensor, a float sensor, a moisture sensor, an acoustic sensor, an ultrasonic sensor, a depth sensor, a distance sensor, weight sensor, or a proximity sensor. In some examples, one or more of the refueling sensors202may be a power supply sensor144.

In some examples, one or more of the refueling output devices204may comprise a display screen, speaker, or haptic device configured to provide an output that can be perceived (e.g., seen, heard, felt, etc.) by a human operator. In some examples, one or more of the refueling output devices204may be positioned on or in the rear panel134or side panel136of the housing130, proximate to the fuel tank300(and/or a neck inlet304of the fuel tank300; see, e.g.,FIG.3), so that an operator refueling the fuel tank300will be able to perceive (e.g., see, hear, feel, etc.) output of the refueling detection system200indicating a volume and/or level of the fuel302in the fuel tank300.

As discussed above, the refueling detection system200is configured to operate even when the welding-type power supply102is turned off, so that an operator can be informed of the volume and/or level of the fuel302in the fuel tank300even if the welding-type power supply102is turned off before refueling. In some examples, this means that the components of the refueling detection system200will continue to receive stored electrical power from the energy storage device152even when none of the other components of the welding-type power supply102receive electrical power from the energy storage device152(e.g., because the power supply102has been turned off). In some examples, the components of the welding-type power supply102may receive, or stop receiving, electrical power from the energy storage device152as a result of the state (e.g., on/off, open/closed, etc.) of one or more controllable circuit elements402of the on/off circuit400.

In some examples, one or more controllable circuit elements402of the on/off circuit400change state(s) (e.g., fire, turn on/off, close/open, etc.) in response to input from the on/off interface154(e.g., turning the power supply102on/off). Thus, in some examples, an operator may turn the power supply102off (and/or on) via the on/off interface154, which may result in a change in state(s) of one or more controllable circuit elements402of the on/off circuit400. A change in state of the controllable circuit element(s)402may, in turn, result in one or more components of the welding-type power supply102receiving, or no longer receiving, electrical power from the energy storage device152.

FIG.4shows an example configuration of the on/off circuit400. In the example ofFIG.4, the refueling detection system200forms one perpetually closed circuit with the energy storage device152. In such a circuit the refueling detection will always receive stored electrical power from the energy storage device152, so long as there remains electrical power stored by the energy storage device152that is available for output.

In the example ofFIG.4, the UI142, engine148, power supply sensor(s)144, and power control circuitry140(collectively referred to hereinafter as on/off components404) are shown connected in series with one another, and connected to the energy storage device152in parallel with the refueling detection system200and the engine starter150. Additionally, there is a controllable circuit element402ain the circuit400between the on/off components404and the energy storage device152. Further, there is a controllable circuit element402bin the circuit400between the on/off components and the engine starter150.

In some examples, instead of being connected in series, the on/off components404may be connected in parallel with one another, so long as the controllable circuit element402alies between each on/off component404and the energy storage device152, and the controllable circuit element402blies between each on/off component404and the engine starter150. Regardless of whether the on/off components404are connected in series or parallel, the on/off components404are dependent upon the state of the controllable circuit element402afor power. In particular, the circuit400is configured such that the state of the controllable circuit element402a(and/or whether the controllable circuit element402acompletes/closes or breaks/opens the circuit400between the on/off components404and the energy storage device152) controls whether the on/off components will receive stored electrical power from the energy storage device152.

In the example ofFIG.4, the engine starter150is connected to the energy storage device152in parallel with the refueling detection system200and on/off components404. As shown, two controllable circuit elements402(402aand402b) are positioned in the circuit400between the engine starter150and the energy storage device152. In this configuration, both controllable circuit elements402must be put into a state where they complete the circuit400before the engine starter150is able to receive stored electrical power from the energy storage device152and start the engine148.

In some examples, each controllable circuit element402may comprise, for example, a switch, relay, and/or transistor (e.g., MOSFET, JFET, IGBT, BJT, etc.). In the example ofFIG.4, each controllable circuit element402is connected to and/or controlled by the on/off interface154. In some examples, the controllable circuit element402may change state (e.g., fire, turn on/off, close/open, etc.) based on, and/or in response to one or more control signals sent by, and/or one or more mechanical actuations initiated by, the on/off interface154.

While not shown, in some examples, the on/off interface154may be connected to the energy storage device152in a perpetually closed circuit configuration, similar to the configuration shown with respect to the refueling detection system200. In such a configuration, the on/off interface154will always receive stored electrical power from the energy storage device152, so long as there remains electrical power stored by the energy storage device152that is available for output. This may ensure that an operator can always turn on or off the on/off components404via control signals from the on/off interface154. In some examples, the on/off interface154may be a purely mechanical (e.g., key) interface, such that no electrical power is required for operation.

In some examples, the control signals and/or mechanical actuations may be sent and/or initiated in response to operator input. For example, the controllable circuit element402amay be a switch, and the operator may move (e.g., turn) a key (or ignition barrel, switch, slide, lever, etc.) of the on/off interface154into a first position that actuates/activates both controllable circuit elements402(e.g., switches) into open positions that break the circuit400, thereby stopping stored electrical power from the energy storage device152from reaching the on/off components404and engine starter150. In such a situation, the engine148and other on/off components404may lose power and/or shut off, and the power supply102may be considered to be off.

Further movement (e.g., turning) of the key into a second position may mechanically actuate the controllable circuit element402a(e.g., switch) into a closed position that completes the circuit400and allows the on/off components404to receive stored electrical power from the energy storage device152. In such a state, the engine148may continue to run (if already running), and the power supply sensors144, power control circuitry140, and the UI142(e.g., fuel gauge) may operate. Further movement (e.g., turning) of the key into a third position may mechanically actuate the controllable circuit element402aand402binto closed positions that complete the entire circuit400and allows both the on/off components404and engine starter150to receive stored electrical power from the energy storage device152(thereby allowing the engine148to start).

The lack of any controllable circuit element402between the refueling detection system200and the energy storage device152means that the refueling detection system200may continue to receive stored electrical power from the energy storage device152, and thus continue to operate, even when the power supply102is turned off (e.g., via the on/off interface154). While this may benefit the operator by allowing for output of a fuel level indication while the power supply102is off (as it should be when refueling), this also means that the refueling detection system200may be a continuous drain on the electrical power stored by the energy storage device152. In order to minimize the continuous drain on the electrical power stored by the energy storage device152, one or more components of the refueling detection system200may operate (and/or default to operation) in a lower power mode until refueling is detected.

In some examples, while in the lower power mode, a refueling sensor202may take samples and/or measurements, and/or send sensor data representative of samples/measurements to the refueling control circuitry206, at a lower rate, so as to use less power. In some examples, while in the lower power mode, the refueling control circuitry206may operate slower and/or at a lower frequency, so as to use less power. In some examples, while in the lower power mode, the refueling output device(s)204may shut down and/or cease providing outputs.

In some examples, the refueling control circuitry206may activate the components of the refueling detection system200that are operating in lower power mode to transition the components to a higher power mode. In some examples, while in the higher power mode, a refueling sensor202may take samples and/or measurements, and/or send sensor data representative of the samples/measurements, at a higher rate than in the lower power mode. In some examples, while in the higher power mode, the refueling control circuitry206may operate faster and/or at a higher frequency than in the lower power mode. In some examples, while in the higher power mode, the refueling output device(s)204may power up and/or provide outputs.

In some examples, the refueling control circuitry206activate the higher power mode in response to determining that the fuel tank300is being refueled. In some examples, the determination may be based on an input from the UI142(e.g., before the power supply102is turned off) indicating that refueling is about to take place. In some examples, the determination may be based on sensor data from one or more of the refueling sensors202.

In some examples, one or more of the refueling sensors202may be used to detect some condition indicative of refueling, from which the refueling control circuitry206may determine whether refueling is occurring. For example, one or more refueling sensors202might be acoustic sensors, and the refueling control circuitry206may be able to recognize sounds that correlate with refueling. As another example, one or more of the refueling sensors202might detect the level and/or volume of the fuel302in the fuel tank (e.g., by way of optical measurements, distance/depth/proximity measurements, a float sensor, etc.), and the refueling control circuitry206may determine refueling is occurring if the sensor data indicates the level and/or volume of the fuel302in the fuel tank300is increasing.

FIG.3show examples of how the refueling sensors202may be placed on, in, and/or around the fuel tank300. As shown, refueling sensors202may be positioned proximate the neck inlet304of the fuel tank300to detect when the fuel tank300is full and/or being refueled. In some examples, fuel302is delivered to the fuel tank300through the neck inlet304during refueling. In some examples, the neck inlet304may have an opening in the housing130of the power supply102, extend out of the (e.g., roof, rear panel134, and/or side panel136of the) housing130of the power supply102. In some examples, the neck inlet304may be accessible via a window (and/or through removal or movement) of a rear panel134or side panel136of the housing130of the power supply102.

Refueling sensors202positioned proximate the neck inlet304may be able to detect when new fuel302is being poured into the fuel tank300(e.g., from a fuel can306), and/or when the fuel tank300is full. For example, a pair of optical emitter/receiver refueling sensors202might report intermittent detection of (and/or optical interruption caused by) fuel302being poured into the fuel tank300, from which the refueling control circuitry206may determine the fuel tank300is being refueled. As another example, a pair of optical emitter/receiver refueling sensors202might report continuous detection of (and/or optical interruption caused by) fuel302in the neck inlet304, from which the refueling control circuitry206may determine the fuel tank300has been refilled to maximum capacity. As another example, a moisture refueling sensor202may detect an increase in moisture in the neck inlet304, from which the refueling control circuitry206may determine the fuel tank300is being refueled, and/or that the volume/level of the fuel302is near the neck inlet304.

Refueling sensors202may also be positioned proximate the top of the fuel tank300, the bottom of the fuel tank, and/or the sides of the fuel tank (e.g., at various heights) to detect when the fuel tank300is full and/or being refueled. For example, a weight refueling sensor202positioned below the fuel tank300may detect a weight of the fuel tank300, from which the refueling control circuitry206may determine the fuel tank300is being refueled (e.g., if the weight is increasing by more than a threshold amount/rate), and/or what the volume/level of the fuel302is in the fuel tank300(e.g., based on a known/stored weight of the fuel tank300when empty/full). As another example, a proximity/distance refueling sensor202positioned at the top of the fuel tank300may measure the proximity/distance to the fuel302in the fuel tank300(e.g., using ultrasonic waves), from which the refueling control circuitry206may determine the fuel tank300is being refueled (e.g., if the proximity/distance is decreasing by more than a threshold amount/rate), and/or what the volume/level of the fuel302is in the fuel tank300(e.g., based on a known/stored distance to the bottom of the fuel tank300when empty). As another example, pairs of optical emitter/receiver refueling sensors202might report continuous detection of (and/or optical interruption caused by) fuel302in the fuel tank300, from which the refueling control circuitry206may determine the fuel302in the fuel tank300is at least at a particular level (e.g., corresponding to the placement of the refueling sensor(s)202).

In the example ofFIG.2, the refueling control circuitry206includes memory circuitry208in electrical communication with processing circuitry210. In some examples, the processing circuitry210may comprise one or more processors, controllers, and/or graphical processing units (GPUs). In some examples, the processing circuitry210may be configured to execute machine readable instructions stored in the memory circuitry208.

In the example ofFIG.2, the memory circuitry208includes (and/or stores) a refueling detection process500. In some examples, the refueling detection process500may comprise machine-readable instructions stored in memory circuitry208and/or configured for execution by the processing circuitry210. In some examples, the refueling detection process500may be implemented via discrete circuitry (e.g., of the processing circuitry210) rather than, or in addition to, instructions stored in the memory circuitry208. While shown as being separate and distinct, in some examples, the refueling control circuitry206may be the same as, and/or share components with, the power control circuitry140.

FIG.5is a flowchart illustrating operation of an example refueling detection process500. In some examples, during the refueling detection process500, the refueling control circuitry206may determine (e.g., from sensor data of the refueling sensor(s)202) whether the fuel tank300is being refueled and/or how much fuel302is in the fuel tank300. During the refueling detection process, the refueling output device(s)204may additionally provide one or more operator perceptible outputs indicative of the level and/or volume of fuel302in the fuel tank300. While some of the disclosure below discusses the refueling detection process500performing certain actions, this should be understood as a shorthand for one or more components of the refueling detection system200(e.g., processing circuitry210, refueling sensor(s)202, etc.) performing the action(s) as part of the refueling detection process500.

In the example ofFIG.5, the refueling detection process500begins by putting the refueling detection system200into a lower power mode at block502, as discussed above. Then, sensor data representative of one or more measurements/detections/samples of the refueling sensor(s)202is obtained from one or more refueling sensors at block504.

In some examples, only sensor data from the refueling sensor(s)202whose data may be used to determine whether the fuel tank300is being refueled may be obtained at block504. In some examples, refueling sensors202that will be used to determine whether refueling is taking place may not be placed into a lower power mode at block502. For example, if sensor data from the refueling sensors202proximate the neck inlet304will be relied upon to determine whether refueling is taking place, those refueling sensors202may remain in a higher power mode, while the rest of the refueling sensors202are put into a lower power mode at block502.

At block506, the refueling detection process500determines whether sensor data from the refueling sensors202(or other data) indicates that refueling is taking place. If not, the refueling detection process500returns to block504. On the other hand, if sensor data from the refueling sensors202does indicate that refueling is taking place, the refueling detection process500proceeds to block508, where the refueling detection system200is put into a higher power mode, as discussed above. In some examples, blocks502-508may be omitted or skipped, such as, for example, if there are only a few refueling sensors202, if the refueling sensors202use minimal power, and/or if the energy storage device152has such a robust storage of energy that depletion is of minimal concern.

In the example ofFIG.5, the refueling detection process500obtains sensor data from (e.g., all of) the refueling sensors202at block510, and thereafter determines the level and/or volume of fuel302in the fuel tank300based on the sensor data at block512. At block514, the refueling detection process500then provides one or more operator perceptible outputs via the refueling output device(s)204. In some examples, the perceptible output may be a visual output in the visible light spectrum that will be visible to a human operator, an audible output within an acoustic range that will be audible to a human operator (e.g., 20 Hz to 20 kHz, 2 kHz to 5 kHz, 0 dB to 120 dB, 50 dB to 85 dB, etc.), and/or a haptic output that will be felt by a human operator.

At block516, the refueling detection process500determines whether one or more fuel level/volume thresholds have been reached. In some examples, the determination may be made based on the fuel level/volume determination at block512.

In some examples, the fuel level/volume threshold(s) may be stored in memory circuitry208. For example, a threshold may be representative of a fuel level/volume where the fuel tank300is has been filled almost to the top, with some room remaining for expansion of fuel302without overflow. As another example, a threshold may be representative of a volume/level of fuel302where the fuel tank300has almost been filled to the top, so that the operator knows that refueling is almost complete.

At block518, the refueling detection process500provides one or more operator perceptible outputs indicating that a particular threshold has been reached via the refueling output device(s)204. In some examples, the output(s) at block518may be different than the output(s) at block514. For example, the refueling detection process500may output a visible fuel gauge that shows the volume/level of fuel302rising at block512, and output an audible tone at block518to indicate that the fuel tank300is full, or almost full. As another example, the refueling detection process500may output a simple blinking light at block514to indicate the level/volume of fuel302is rising, and output a solid light at block516to indicate that the fuel tank300is full. In some examples, block514may be omitted, and an output only provided when a threshold is reached (at block518), which may, for example, save on the amount of stored energy used by the refueling detection system.

In the example ofFIG.5, the refueling detection process500determines whether a threshold (e.g., stored) amount of time has passed since reaching the threshold(s) level(s)/volume(s) of fuel302at block520. If the amount of time has not passed, the refueling detection process500returns to block510. If the threshold amount of time has passed, the refueling detection process500returns to block502, where the refueling detection system200is once again put into the lower power mode.

The disclosed refueling detection system200provides user perceptible outputs from refueling output devices204positioned proximate the fuel tank300(and/or fuel tank inlet304), so that the output can be perceived by the operator when refueling. The outputs may indicate how much fuel302is in the fuel tank300, and/or whether the fuel tank300has been filled to capacity, so the operator knows when to stop refueling. The refueling detection system200is additionally configured to operate even when the power supply102is turned off, in case the power supply102is turned off prior to refueling (as is the best practice).

As utilized herein, the terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations.

As used herein the terms “circuits” and “circuitry” refer to physical electronic components (i.e., hardware) and any software and/or firmware (“code”) which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware. As used herein, for example, a particular processor and memory may comprise a first “circuit” when executing a first one or more lines of code and may comprise a second “circuit” when executing a second one or more lines of code. As utilized herein, circuitry is “operable” and/or “configured” to perform a function whenever the circuitry comprises the necessary hardware and/or code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).

As used herein, a control circuit may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, DSPs, etc., software, hardware and/or firmware, located on one or more boards, that form part or all of a controller, and/or are used to control a welding process, and/or a device such as a power source or wire feeder.

As used herein, the term “processor” means processing devices, apparatus, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable. The term “processor” as used herein includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC), a graphic processing unit (GPU), a reduced instruction set computer (RISC) processor with an advanced RISC machine (ARM) core, etc. The processor may be coupled to, and/or integrated with a memory device.

As used, herein, the term “memory” and/or “memory device” means computer hardware or circuitry to store information for use by a processor and/or other digital device. The memory and/or memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like. Memory can include, for example, a non-transitory memory, a non-transitory processor readable medium, a non-transitory computer readable medium, non-volatile memory, dynamic RAM (DRAM), volatile memory, ferroelectric RAM (FRAM), first-in-first-out (FIFO) memory, last-in-first-out (LIFO) memory, stack memory, non-volatile RAM (NVRAM), static RAM (SRAM), a cache, a buffer, a semiconductor memory, a magnetic memory, an optical memory, a flash memory, a flash card, a compact flash card, memory cards, secure digital memory cards, a microcard, a minicard, an expansion card, a smart card, a memory stick, a multimedia card, a picture card, flash storage, a subscriber identity module (SIM) card, a hard drive (HDD), a solid state drive (SSD), etc. The memory can be configured to store code, instructions, applications, software, firmware and/or data, and may be external, internal, or both with respect to the processor.

The term “power” is used throughout this specification for convenience, but also includes related measures such as energy, current, voltage, and enthalpy. For example, controlling “power” may involve controlling voltage, current, energy, and/or enthalpy, and/or controlling based on “power” may involve controlling based on voltage, current, energy, and/or enthalpy.

As used herein, a welding-type tool refers to a tool suitable for and/or capable of actual live, and/or simulated, welding (including laser welding and/or hot wire welding), cladding (including laser cladding), brazing, plasma cutting, induction heating, carbon arc cutting or gouging, hot wire preheating, and/or resistive preheating.

As used herein, welding-type power refers to power suitable for actual live welding (including laser welding and/or hot wire welding), cladding (including laser cladding), brazing, plasma cutting, induction heating, carbon arc cutting or gouging, hot wire preheating, and/or resistive preheating.

As used herein, a welding-type power supply and/or welding-type power source refers to a device capable of, when input power is applied thereto, supplying output power suitable for actual live welding (including laser welding and/or hot wire welding), cladding (including laser cladding), brazing, plasma cutting, induction heating, carbon arc cutting or gouging, hot wire preheating, and/or resistive preheating; including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.

As used herein, disable may mean deactivate, incapacitate, and/or make inoperative. As used herein, enable may mean activate and/or make operational.

Disabling of circuitry, actuators, and/or other hardware may be done via hardware, software (including firmware), or a combination of hardware and software, and may include physical disconnection, de-energization, and/or a software control that restricts commands from being implemented to activate the circuitry, actuators, and/or other hardware. Similarly, enabling of circuitry, actuators, and/or other hardware may be done via hardware, software (including firmware), or a combination of hardware and software, using the same mechanisms used for disabling.