Abstract:
A welder having an internal shielding gas regulator is disclosed. The welder has an internal gas cylinder and an internal regulator disposed in an enclosure. The welder may be equipped with an auxiliary shielding gas cylinder inlet so that a bulk shielding gas cylinder can be attached thereto and have a flow therefrom regulated by the internal shielding gas regulator. The welder constructed according to the invention is highly transportable, compact, and self-sufficient.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     The present application is a divisional and claims priority of U.S. patent application Ser. No. 10/707,411 filed Dec. 11, 2003, the disclosure of which is incorporated herein. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to welding systems and, more particularly, to a welder having an integrated regulator.  
         [0003]     Welder power sources have become increasingly portable in recent years. This portability is largely the result of lighter unit weight and improved electrical components. One advancement in the area of electrical components has been the incorporation of inverter-type power sources. The application of an inverter power source has reduced the size and weight of welders and created usable space within the confines of the housing, while maintaining the ability to generate the outputs required for welding. Similarly, advances in battery technology allow the incorporation of an energy storage device in a welder to allow easy transport.  
         [0004]     Improvements in wire feeder technology have also improved the ease of use and portability of a welder. Gas metal arc welding (GMAW) is becoming more widely accepted, and provides cleaner welds by less experienced welders. As a result, due to the ease of use and versatility of application, many users prefer gas metal arc welding over conventional stick welding.  
         [0005]     Space in any work environment is always at a premium. Whether the welder is used in the hobbyist&#39;s garage or the machine shop of an industrial plant, the size of the unit is always a design consideration. The space used by a welder is not limited to the dimensions of the power source itself but includes the ancillaries related to welding processes such as cables, consumables, gas cylinders, and regulators. The space required for the storage and maintenance of these items is another consideration associated with many welders.  
         [0006]     Shielding gas cylinders provide an inert gas to the welding process. This inert gas encapsulates the welding process in order to protect the integrity of the weld from contaminants and also enhances arc performance during a welding process. The shielding gas is generally provided in very large and very heavy cylinders. The flow from these cylinders to the welder is generally controlled by a regulator. The regulator generally has a valve used to control the flow of gas from the cylinder and a gauge used to determine the amount of gas left in the cylinder. The regulator is attached to the cylinder which is usually located behind the welder. Such a location leaves the regulator susceptible to the accumulation of dirt and debris associated with the welding process as well as placing access to the valve and gauge away from the control panel when located on or near the bottle.  
         [0007]     The size and weight of the gas cylinders significantly detracts from the portability of the welder. Additionally, moving the welder with the gas cylinder and regulator removably attached thereto presents an opportunity for inadvertent damage to the regulator. The position of the regulator, at the top of the gas cylinder, and the awkward shape of the combination, is detrimental to portability and can be a reason for advanced wear or damage of the regulator.  
         [0008]     It would therefore be desirable to design a welding-type system and method that includes internal regulation in the housing of the welder power source.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0009]     The present invention is directed to a welder that solves the aforementioned drawbacks. The present invention provides a system and method for a welder that is portable and includes a regulator therein. The regulator is constructed to engage a shielding gas cylinder and provides user control of the regulator from a location outside of the power source.  
         [0010]     Therefore, in accordance with one aspect of the present invention, a welding-type apparatus has a power source constructed to output an electrical signal suitable to welding and a shielding gas regulator disposed within an enclosure. The shielding gas regulator contained within the enclosure is constructed to deliver a shielding gas from a gas cylinder to a weld. Such a construction provides readily accessible control, protects the shielding gas regulator from dirt and debris associated with the welding environment, and improves the portability of the welding-type power source.  
         [0011]     In accordance with another aspect of the present invention, a welding-type device has a base and a cover forming a housing with a welding power source disposed therein. The welding power source is constructed to generate a signal suitable to welding. A first gas path, constructed to provide shielding gas to a weld, originates at a regulator and is located within the housing. The welding-type device has a second gas path also constructed to provide shielding gas to a weld. Such a construction allows for two gas cylinders to be connected to the welding-type device concurrently, thereby improving the versatility of the welding-type device.  
         [0012]     In accordance with a further aspect of the present invention, a method of constructing a welding-type apparatus includes providing a power source constructed to provide a signal suitable to welding, a regulator constructed to engage a welding gas cylinder, and enclosing the power source and the regulator in a common enclosure. Such a construction provides improved portability of the welding-type device.  
         [0013]     Therefore, the present invention provides a welder with a shielding gas regulator housed therein. Such a construction allows for a welding-type power source that is lightweight and transportable with a regulator securely housed therein.  
         [0014]     Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention.  
         [0016]     in the drawings:  
         [0017]      FIG. 1  is a perspective view of the power source according to the present invention.  
         [0018]      FIG. 2  is a perspective view of an alternative embodiment of the power source of  FIG. 1 .  
         [0019]      FIG. 3  is a perspective view of the alternative embodiment of the power source of  FIG. 1  with the cover removed.  
         [0020]      FIG. 4  is a schematic representation of the shielding gas supply system of the power source shown in  FIG. 1 .  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     As one skilled in the art will fully appreciate, the hereinafter description of welding devices not only includes welders but also includes any system that requires high power outputs, such as heating and cutting systems, that require regulated flows of a shielding gas. Description of a welding-type apparatus illustrates just one embodiment in which the present invention may be implemented.  
         [0022]     Referring now to  FIG. 1 , a perspective view of a welding device incorporating the present invention is shown. Welding device  10  includes a housing  12  enclosing the internal components of the welding device under a cover  14 . Optionally, the welding device  10  includes a handle  16  for transporting the welding system from one location to another. To effectuate the welding process, such as TIG or MIG welding, the welding device includes a torch  18  as well as a work clamp  20 . The work clamp  20  is configured to ground a workpiece  22  to be welded. As is known, when the torch  18  is in relative proximity to workpiece  22 , a welding arc or cutting arc results, depending upon the particular welding desired. A pair of cables  24  and  26  connects the torch  18  and work clamp  20  to the housing  12 , respectively.  
         [0023]     As shown in  FIG. 1 , cover  14  has a door  28  located therein which allows access to an interior of welding device  10 . Door  28  covers an opening  30  in housing  12  and has a hinge  32  connecting door  28  thereto. Opening  30  is configured to allow for the passage of an internal shielding gas cylinder  34  (shown in phantom under cover  14 ) therethrough. Hinge  32  of door  28  allows door  28  to be pivotally opened and closed over opening  30 . The hinge may also be placed on a bottom side  36  of door  28 .  
         [0024]     A control panel  38  is located in an upper portion  40  of a front panel  42  of housing  12 . An on/off switch  44  and an output power control  46  are also located in control panel  38  of front panel  42 . It is understood that output control  46 , although shown as a single variable control, could be configured as several independent controls to control variable parameters of the power source such as wire feed speed, voltage, or current. A pressure gauge  48  and a valve  50  are located in control panel  38  of front panel  42  and provide an operator with a means of readily determining and controlling shielding gas flow to torch  18 .  
         [0025]      FIG. 2  shows an alternate embodiment of the opening for the internal shielding gas cylinder  34 . Preferably, a cover  52  threadingly engages a rear panel  54  of housing  12 . Cover  52  is removable to allow for placement of internal shielding gas cylinder  34  into a gas cylinder chamber  56 . Cover  52  can be constructed to retain a base  58  of internal shielding gas cylinder  34 . In this manner, a support  60  is provided at a front end  62  of gas cylinder chamber  56  and internal shielding gas cylinder  34  is effectively retained between support  60  and cover  52 . Although shown as positioned in a rear or a side panel of the housing, such openings are only by way of example and do not limit the scope of the claims presented herein.  
         [0026]      FIG. 2  also shows a first embodiment of a means of retaining the gas cylinder in welder  10 . Cover  52  extends into an interior of welding device  10  by extending past rear panel  54 . Cover  52  is constructed to engage base  58  of internal shielding gas cylinder  34  and thereby creates a compressive force generally indicated by arrow  64  between support  60  and rear panel  54  of housing  12  with internal shielding gas cylinder  34  disposed therebetween. The construction of support  60  and cover  52  secure internal shielding gas cylinder  34  relative to a power source within housing  12  of welder  10 . Although not shown in  FIG. 2 , it is understood that the control panel  40  of this embodiment is similar to the control area shown in  FIG. 1 . That is, regardless of the means for providing shielding gas to the torch, by positioning the valve and gauge of a shielding gas regulator in the general vicinity of the control panel of the welding-type device, an operator has ready access to the control and operation of the shielding gas from a convenient location.  
         [0027]      FIG. 3  shows a detailed view of the embodiment of  FIG. 1  with cover  14  removed to expose an interior  66  of welding device  10  and having connected thereto an optional secondary source of welding gas  92 . A wire feeder  68  is disposed in interior  66  of welding device  10  and in electrical communication with a power source  70 , also located therein and attached to a base  72  of housing  12 . Wire feeder  68  provides a consumable material, such as wire  74 , to torch  18  during the welding process. Shielding gas is provided to torch  18  during the welding process from internal shielding gas cylinder  34 . An operator can monitor and control the flow of shielding gas delivered to torch  18  by adjusting valve  50  and monitoring gauge  48  located in control panel  38  of front panel  42 .  
         [0028]     Internal shielding gas cylinder  34  is located within housing  12  of welding device  10  and held in place by a means for retaining the gas cylinder, in this embodiment, a restraint  76 . Restraint  76  maintains the position of internal shielding gas cylinder  34  relative to power source  70 . A body  78  of internal shielding gas cylinder  34  extends between base  58  and an outlet end  80 . Outlet end  80  of internal shielding gas cylinder  34  is constructed to engage a first adapter  82  of an internal regulator  84 . The means for retaining  76  can be of many different configurations such as that shown with reference to  FIG. 2 , as discussed above, or, as that shown in  FIG. 3 , a pair of straps  86 ,  88  that hold body  78  of internal shielding gas cylinder  34  and prevent movement of internal shielding gas cylinder  34  relative to power source  70  and internal regulator  84 . Such a construction prevents the inadvertent disengagement of internal shielding gas cylinder  34  from first adapter  82  of internal regulator  84 .  
         [0029]     Also shown in  FIG. 3 , first adapter  82  of internal regulator  84  is constructed to engage outlet end  80  of internal shielding gas cylinder  34  inside housing  12  and still allow a user control over the function of internal regulator  84 . Gauge  48  and valve  50  extend from internal regulator  84  through front panel  42  of housing  12 . Valve  50  and gauge  48  allow a user to adjust and determine the delivery pressure of shielding gas to torch  18  from internal shielding gas cylinder  34  and are positioned in control panel  38  of front panel  42  so that a majority of the controls of the welding-type device, including the control of the delivery pressure of the shielding gas, are adjustable from the control panel  38  of device  10 . In addition to first adapter  82 , internal regulator  84  is also connected to a housing adapter  90 , which is discussed below.  
         [0030]     Housing adapter  90  extends from internal regulator  84  through rear panel  54  of housing  12  and is constructed to engage optional secondary source of welding gas  92 . Optional secondary source of welding gas  92  also has a regulator  94  attached thereto. A connection means  100  extends from regulator  94  to housing adapter  90  of welding device  10 . This construction provides for the connection of a second shielding gas cylinder to the welding device when desired, such as when the welder is located at a primary operating position such as a shop or a garage. Additionally, this construction provides that the shielding gas cylinder located within the welding device is reserved for remote operations away from the bulk shielding gas cylinder. The construction also prevents excessive changing of gas cylinders when a bulk shielding gas cylinder is available. Additionally, the user is not required to transport a heavy and awkward bulk cylinder, but can simply disconnect the bulk cylinder at housing adapter  90  and move the welding-type device to a desired position with internal shielding gas cylinder  34  located securely within housing  12 .  
         [0031]      FIG. 4  shows a schematic representation of a shielding gas system  102  of the welding device  10  in accordance with one embodiment of the invention. Outlet end  80  of internal shielding gas cylinder  34  engages first adapter  82  of internal regulator  84 . Pressure gauge  48  and control valve  50  of internal regulator  84  pass through housing  12  and indicate conditions of a shielding gas path  104 . Shielding gas path  104  passes through a first inlet  106  of a T-connector  108  and into a valve  110 . T-connector  106  has a second inlet  112  that is connected by a second gas path  114  to a nipple  116  of housing adapter  90 . Valve  110  has an outlet  118  that is connected by a gas path  120  to a drive roll assembly  122 . Drive roll assembly  122  is electronically connected  124  to control the on/off actuation of valve  110  such that shielding gas is provided when a trigger of torch  18  is activated. As such, valve  110  controls the flow of shielding gas to torch  18  from internal shielding gas cylinder  34  and optional secondary source of welding gas  92 .  
         [0032]     Housing adapter  90  extends through housing  12  and is rigidly mounted to housing  12 . Housing adapter  90  also acts as a check valve and prevents the passage of shielding gas therethrough when a first end  126  of connector means  100  is not connected thereto. The engagement between housing adapter  90  and first end  126  of connection means  100  is such that the two components can be fluidly connected without needing additional tools. Such a connection is commonly referred to as a quick connection or a quick coupler. Connection means  100  has a second end  128  connected to secondary regulator  94  of optional secondary source of welding gas  92 . This construction allows for quickly connecting and disconnecting optional secondary source of welding gas  92  from welding device  10 . As such, when it is desired to utilize the welding device in a remote location away from such an auxiliary bulk shielding gas cylinder, connection means  100  and housing adapter  90  are disconnected at either of first or second ends  126 ,  128 . The welding device can then be operated remotely with internal regulator  84  and internal shielding gas cylinder  34  to provide regulated shielding gas for welding. This construction provides that the gas cylinder located within the welding device is reserved for remote operations away from the bulk tank. By using the bulk shielding gas cylinder whenever available, replacing or refilling of the internal gas cylinder is minimized.  
         [0033]     The invention can be used in any welding-type apparatus, and is especially applicable to TIG and/or MIG welding processes. It is also noted that the regulator may be used to control a flow of inert or another suitable gas/mixture suitable for such uses. In general then, the invention is applicable to any of the aforementioned welding-type applications that would benefit from an internally regulated shielding gas flow.  
         [0034]     Therefore, in accordance with one embodiment of the present invention, a welding-type apparatus includes a power source constructed to output an electrical signal suitable to welding and a shielding gas regulator disposed within an enclosure.  
         [0035]     In accordance with another embodiment of the present invention, a welding-type device has a housing having a base and a cover. A welding power source is disposed in the housing and is constructed to generate a signal suitable to welding. A first gas path originates at a regulator located in the housing and is constructed to provide shielding gas to a weld. The welding device has a second gas path that is also constructed to provide shielding gas to a weld.  
         [0036]     In accordance with a further embodiment of the present invention, a method of constructing a welding-type apparatus is disclosed that includes providing a power source constructed to provide a signal suitable to welding, providing a regulator constructed to engage a welding gas cylinder, and enclosing the power source and the regulator in an enclosure.  
         [0037]     The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.