Enclosed welder with recess panel

Embodiments of an enclosed welder that includes a recess disposed at a depth in a rear panel of the enclosure are provided. The recess may include at least one of an engine air filter, a blower housing, and a recoil start. The depth at which the recess is set back from the rear panel may be such that the engine air filter, the blower housing, and the recoil start each do not extend outward beyond the rear panel. A first air source may be configured to enter the enclosed welder via the air filter and combust fuel within an engine. A second air source may further be configured to enter the welder via the blower housing and cool the engine.

BACKGROUND

The invention relates generally to welding devices, and more particularly, to a welder with a small combustion engine.

Welding is a process that has increasingly become ubiquitous in various industries and applications. While such processes may be automated in certain contexts, a large number of applications continue to exist for manual welding operations, which rely on the use of an engine-driven welder/generator to power the welding process. Specifically, welders with small internal combustion engines are often used in applications such as small scale maintenance and repair work, farm and ranch welding, and small scale construction, among others. Such welders typically include functional components such as electrical circuitry, a generator, the single cylinder engine, a muffler, and the like, which produce substantial amounts of heat during operation.

Welders with small internal combustion engines are typically provided in open frame models, in which the engine, among other components, remains unenclosed. These welders typically provide a low cost portable system for use in small scale welding applications. However, such welders leave the engine, as well as other components, exposed to the welding environment. Since welding environments typically include harsh conditions, such as weld splatter and extreme heat, weld components may be damaged during use. Accordingly, there exists a need for improved welders with engine-driven generators that overcome these drawbacks.

BRIEF DESCRIPTION

Embodiments of an enclosed welder that includes a recess extending into a rear panel of an enclosure are provided. The recess may include at least one of an engine air filter, a blower housing, and a recoil start. The depth at which the recess is set back from the rear panel may be such that the engine air filter, the blower housing, and the recoil start each do not extend outward beyond the rear panel. The enclosed welder may include a small engine suitable for use in small scale welding operations, among others. Certain embodiments of the welder may include one or more air sources that are configured to enter the welder at a cool temperature and exit the welder at a significantly higher temperature. A first air source may be configured to enter the welder via the air filter located in the recess and direct the air into the engine for use in the combustion process. A second air source may be configured to enter the welder via the blower housing located in the recess and cool the engine.

DETAILED DESCRIPTION

As discussed in detail below, embodiments are described of an enclosed welder that includes a recess extending into a rear panel of the enclosure. In certain embodiments, the recess may include at least one of an engine air filter, a blower housing, and a recoil start. The depth at which the recess is set back from the rear panel may be selected such that the engine air filter, the blower housing, and the recoil start each do not extend outward beyond the rear panel. The foregoing features may have the effect of facilitating a manual restart of a single cylinder engine located inside the enclosure without the disassembly of parts of the welder or even the removal of access panels. Furthermore, the aforementioned features may also facilitate the maintenance and replacement of the engine air filter, since the filter may be accessed without exposing the internals of the welder.

In presently contemplated embodiments, the welder may include a small (e.g., single cylinder) engine suitable for use in small scale welding operations. Certain embodiments of the welder may include one or more air sources that are configured to enter the welder at a cool temperature and exit the welder at a significantly higher temperature. Specifically, in some embodiments, a first air source may be configured to enter the welder via the air filter located in the recess and be utilized as combustion air within the engine. In further embodiments, a second air source may be configured to enter the welder via the blower housing located in the recess and cool the single cylinder engine within the enclosure. Still further, a third air source may be configured to enter a front of the welder and cool electrical components located within the enclosure.

Turning now to the drawings,FIG. 1is a perspective view of an exemplary enclosed welder10that may be used to perform a variety of welding processes, such as shielded metal arc welding (SMAW) processes (e.g., stick welding) and gas tungsten arc welding (GTAW) processes (e.g., tungsten inert gas (TIG) welding). It should be noted that although embodiments of the present invention are discussed in the context of a welder, the disclosed systems and devices may be used in other suitable contexts, such as plasma cutting. In the illustrated embodiment, the welder10includes an enclosure12that encompasses a variety of internal components, such as a single cylinder engine, a muffler, fans, electrical components, and the like. That is, in embodiments of the present invention, the enclosure12fully envelopes functional components of the welder10, thereby reducing or preventing physical damage to internal components due to exposure to harsh conditions that may be present in welding environments (e.g., extreme heat, weld splatter, jobsite debris, and so forth). For example, in the embodiment illustrated inFIG. 1, the engine is fully enveloped by the enclosure12such that particulates in the welding environment may be prevented from entering the engine, and the potential for damage to components of the engine may be reduced or prevented.

The enclosure12includes a rear panel14that covers a back of the welder10. The rear panel14includes a recessed panel16, which is set back from the rear panel14by a depth18. The recessed panel16includes openings to expose the engine air filter20. The recessed panel16also includes an engine blower housing24coupled to a recoil start26that includes a recoil knob27. The enclosure12also includes a top panel28with a first set of vents30and a second set of vents32as well as a side panel34with a set of vents36. The vents30,32,36may be used to vent heated air from within the enclosure12to the surrounding environment.

The depth18at which the recessed panel16is set back from the rear panel14may be any of a variety of amounts suitable for the given welder10and application. For example, in one embodiment, the depth18may be approximately 3″ such that the engine air filter20, the engine blower housing24, and the recoil start26do not extend in an outward direction beyond the rear panel14. Furthermore, in some embodiments, the recessed panel16may be set back by any suitable depth18such that the air filter20, blower housing22, and recoil start26do not extend beyond the rear panel14. Such a feature may have the effect of facilitating the accessibility of the engine air filter20and the recoil start26to the operator while protecting such components from damage during transportation, storage, and/or use. For instance, the position of the air filter20outside the enclosure12but within the recessed panel16may provide the operator with easy access to the filter20for maintenance purposes (e.g., filter changes or cleanings). That is, the air filter20may be replaced without removal of engine access panels, disassembly of machine parts, and so forth. Further, the location of the recoil start26external to the housing12but within the recessed panel16may facilitate an efficient restart of the welder10in the event of battery failure. That is, the operator may manually restart the welder10in such instances without disassembly of machine parts, removal of engine access panels, and so forth. Specifically, the operator may grip the recoil knob27and pull in a direction away from the welder10. Such pulling of the recoil knob27causes a rope connected to the knob27to uncoil around the end of a crankshaft located in the housing12, thus spinning the crankshaft and starting the engine. In this way, after failure, the engine may be manually restarted from within the recess16but external to the enclosure12.

FIG. 2is a rear perspective view of the welder10illustrating components disposed in the recess16in more detail. As shown, the recess16includes the air filter20, the engine blower housing24, and the rope start26. During operation, such components disposed in the recess16may facilitate the exchange of air between the surrounding environment and internal components of the welder10. For example, a first air source, as represented by arrows38, may enter the enclosure12via the air filter20. After entering the air filter20, the first air source38may be the combustion air used to fuel the combustion process in the engine. That is, air source38may enter the air filter20, be received by the engine, and be utilized as the oxidizing element in a fuel combustion process. Indeed, in presently contemplated embodiments, combustion air being supplied to the engine via the air filter20enters the enclosure12from the outside of the enclosure12where the air temperature is ambient. The foregoing feature may offer advantages over systems wherein hot air from within the enclosure12is used as combustion air. After use, combustion products38may be expelled from within the enclosure12via a muffler located in the top panel28of the welder10. By further example, a second air source, as represented by arrows40, may be drawn into the enclosure12via the engine blower housing24. Once inside the welder10, the second air source40may be used for engine cooling purposes. That is, the second air source40may be circulated over or through the engine to reduce its temperature. After cooling the engine, the second air source40may be expelled from within the housing12via one or more of vents30,32,36, and/or vents located in a second side panel opposite side panel34.

Furthermore, it should be noted that additional air flow paths may be established through the welder10. For example, one or more air sources may enter the welder10via a front panel (not shown) opposite the rear panel14. Specifically, in one embodiment, a third air source may enter the front panel, circulate over a generator for cooling purposes, and exit the welder10via vents30,32,36, and/or vents located in the second side panel opposite side panel34. In still further embodiments, one or more of the air paths may be combined within the welder10but after use such that the used air exits the housing12at a common location.

FIG. 3is a perspective view of the welder10ofFIGS. 1 and 2that illustrates an exemplary air path42that air source40may follow during cooling of the engine. As before, air source40enters the welder10via blower housing24. Upon entrance into the enclosure12, the air travels along an air path42that directs the air through the welder10. Specifically, air entering the unit through blower housing24is directed over or through the engine, thus cooling the engine, as indicated by portion44of air path42. After cooling of the engine, the heated air splits at junction point46. In the illustrated embodiment, a first portion of the heated air follows path48and exits the welder10via vents32. A second portion of the heated air follows path50to exit through the vents36in the side panel34. In further embodiments, the heated air may be broken up into additional portions, which may exit the welder10via additional vents, such as the vents30.

During operation, the air source40may include air that is significantly cooler than the engine. As the air contained in the air source40is circulated through the welder10to cool the engine, a temperature of the air will be increased. Accordingly, the first air portion and the second air portion exiting the welder along path48and path50, respectively, will be at a higher temperature than the incoming air source40. In other words, air entering the blower housing24will be cooler than the air exiting through the vents30,32,36.

FIG. 4is a top perspective view of the welder10with the top panel28and the side panel34removed, thereby illustrating internal components of the welder10. Internal components of the welder10may include an engine52, a generator, electrical components54, fans, and so forth. The engine52may be any of a variety of one cylinder engines suitable for welding or plasma cutting applications. Further, such engines may be capable of producing any of a variety of amounts of horsepower (HP), operating at any suitable speed, accommodating a variety of fuel capacities, and holding any suitable oil capacity. For example, in one embodiment, the engine may be a Subaru EX40 model capable of approximately 14 HP at approximately 3600 RPM and top engine speeds of approximately 3750 RPM. For further example, in another embodiment, the engine may be a Subaru EX30 model capable of approximately 9.5 HP at approximately 3600 RPM and top engine speeds of approximately 3750 RPM.

In certain embodiments, the electrical components54may include rectifiers, reactors, stabilizers, electronic modules, PC boards, and so forth. The electrical components54may be generally designed to be maintained at an operating temperature less than a designated level, such as less than approximately 130° C. The engine52may also be generally designed to be maintained at an operating temperature less than a designated level, such as less than approximately 150° C. Accordingly, the one or more air flow paths previously discussed may cool the electrical components54, the engine52, or both during operation.