Abstract:
A method and apparatus of communicating control signals to a welding power source from a remote location includes a welding system operated by control signals transmitted by a wireless remote control that can be remotely located from the welding power source. A plurality of welding parameters in the welding system are set and adjusted in response to wireless command signals transmitted to a receiver that is connected to the welding power source via a connection port and is further connected to a controller in the welding power source. In this regard, an operator is able to quickly and efficiently control a welding system from a remote location, with no more cables than are necessary to perform the intended task.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to welding machines and, more particularly, to a method and apparatus of communicating control signals to a welding power source from a remote location. Specifically, the invention relates to a welding system whose operation is governed by control signals transmitted by a wireless remote control. A plurality of welding parameters in the welding system are set and adjusted in response to wireless command signals received by the welding power source. In this regard, an operator is able to quickly and efficiently control a welding system from a remote location, with no more cables than are necessary for welding. 
     Welding and cutting are essential operations in many different areas of manufacturing and construction in today&#39;s economy. The versatility and efficiency of welding and cutting systems is vital to, and allows for, the efficient completion of many complex and dynamic welding operations. In many welding and cutting processes performed by operators, welding-type systems are adjusted during the process to accommodate several different welding-type operations. When the need for such adjustments arise, the welding parameters in the welding-type system need to be properly set for each different welding-type process. In each of these processes, parameters need to be set and adjusted prior to and during the welding-type process. In many instances, the welding-type process takes place at a distance from the actual welding machine/power source. Thus, an operator is required to walk back to the machine to make any necessary adjustments. To overcome this problem, some welding-type systems have started to incorporate some form of remote control. In many existing systems, power and communications between an operator location and a welding-type power source location are transmitted over cables. These cables provide a simple and reliable means for communication and control of various welding parameters. 
     Despite the benefits of such a set-up, there are also numerous drawbacks associated with communication and control of the welding-type system in such a manner. One drawback to this cable-based control is that the communications cable is typically fragile relative to the welding cables designed to carry high currents at high voltages. Welding-type systems are often used at sites where it is not uncommon for the systems to be periodically relocated or surrounded by other mobile heavy equipment operating in the same area. As such, the remote control communications cable can become damaged by being crushed or snagged from contact with surrounding machines and/or traffic. This can cause damage to the welding-type power source if internal power conductors become shorted to signal leads that are connected to sensitive signal level circuitry and obviously reduce productivity. 
     Communications cables for remote control of a welding device also produce additional concerns. One of these concerns is the introduction of high frequency electrical noise to the welding-type system, which occurs because of the high voltages present in the environment surrounding the communications cable. The communications cable provides a conduit for the noise to enter the power source and controller of the welding-type system. This noise and interference must be filtered out so as not to negatively affect the performance of the system. 
     Because of the numerous drawbacks associated with communication cables for remote control of a welding-type system, attempts have been to modify the manner of communication in newer systems. Various types of remote control devices have been introduced to facilitate operator control of the welding-type processes thru a means other than just a standard communications cable. However, while newly designed systems can be designed to include such wireless remote control devices, a problem persists regarding existing welding systems not currently configured to allow for operation via a wireless remote control. Therefore, a need remains for a system able to retrofit an existing welder with a remote device capable of controlling a welding operation in a manner that is practical and efficient for an operator. 
     A remote control device that can be incorporated into existing welding systems and that can wirelessly control a plurality of welding processes is a feature that would greatly enhance the productivity of existing welding systems. Eliminating the communications cord with a wireless remote control would overcome many of the problems associated with high frequency electrical noise as described above. A wireless remote control would also provide for many benefits and conveniences for an operator, such as reducing the inconvenience of extra cables. Removal of a communication cord also would eliminate the possibility of communications being damaged due to sparks, hot metal and heavy objects falling on the cord and increase portability of a welding system. The elimination of extra cords also would allow for more convenient use of the welding system in confined areas. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention overcomes the aforementioned drawbacks and adds the stated benefits by providing a welding-type system capable of wirelessly controlling various welding parameters from a remote location. The welding-type system includes a welding power source having a controller, a welding torch, a wireless remote control capable of controlling a plurality of parameters in a welding system, and a receiver. 
     Therefore, in accordance with one aspect of the present invention, a welding-type system is disclosed that includes a power source having a controller to regulate welding operations and a welding torch connected to the power source. The system also includes a wireless remote control configured to remotely transmit a signal for controlling a plurality of welding parameters in the welding system, and a receiver remote from the wireless control and configured to receive the signal and allow the controller to regulate at least one of the plurality of welding parameters in response thereto. The receiver is further configured to engage a connection port located on the power source, the connection port configured to engage both the receiver and a control cable. 
     In accordance with a further aspect of the present invention, a wireless remote control kit for retrofitting a welding-type apparatus is provided. The wireless remote control kit includes a wireless control configured to transmit a signal to control a plurality of welding parameters in a welding-type apparatus suitable for producing a welding-type power. The wireless remote control kit further includes a receiver remote from the wireless control and configured to receive and relay the signal to the welding-type apparatus. The receiver is operatively connected to a controller housed in a power source of the welding-type apparatus. 
     According to yet a further aspect of the invention, a method for adapting an existing welding-type system for use with a wireless remote control is disclosed. The method includes the steps of connecting a receiver to a welding-type power source by way of an existing control cable connection port, wirelessly transmitting a signal from the wireless remote control indicative of desired operational parameters of the welding-type system, receiving the signal remotely by way of the receiver, and controlling the welding-type system in accordance with data embodied in the received wirelessly transmitted signal. 
     Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention. 
       In the drawings: 
         FIG. 1  is a perspective view of a welding-type system and remote control communication system for controlling a welding-type device according to the present invention. 
         FIG. 2  is a perspective view of the welding-type system of  FIG. 1  and a detailed view of a connection port thereon. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  shows a welding-type system capable of performing various types of operations. The welding-type system  10  is merely representative of a wide variety of welding-type machines having various sizes, features, and ratings. The welding-type system, as contemplated herein, can be configured to not only perform standard welding type operations such as TIG, MIG, and/or stick welding, but can also be capable of performing various cutting operations that are closely associated with the various welding procedures, such as plasma cutting for example. In the exemplary embodiment of  FIG. 1 , the welding-type system shown is preferably a tungsten inert gas (TIG) welding system, however, one skilled in the art will readily appreciate that it may be any related welding or cutting system, including those listed above. TIG welding system  10  includes a power source  12  to condition raw power and generate a power signal suitable for welding applications. Power source  12  includes a processor/controller  13  that receives operational feedback and monitors the operation of TIG welding system  10 . Connected to power source  12  is a torch  16  via a cable  18 . Cable  18  provides torch  16  with power and compressed air or gas, where needed. Torch  16  includes a handle portion  29 , or torch body, having a trigger  31  thereon to actuate the torch and work tip  32  extending therefrom. 
     Also connected to power source  12  is a work clamp  20  which is designed to connect to a workpiece (not shown) to be welded and provide a return path. Connecting work clamp  20  to power source  12  is a cable  22  designed to provide the return path for the welding current from torch  16  through the workpiece and work clamp  20 . Extending from a rear portion  23  of power source  12  is a power cable  24  having a plug  26  for connecting power source  12  to either a portable power supply (not shown) or a transmission line power receptacle (not shown). Also connected to the power source is a gas source  33  configured to supply a gas flow to the welding torch  16 . 
     To allow for wireless operation of the welding-type system  10  from a location remote from power source  12 , wireless remote control  50  and receiver  36  are included in welding-type system  10  and configured to set and adjust operational parameters therein. Wireless remote control  50  is located remote from the welding-type power source  12  during a welding-type operation and communicates with receiver  36 . Receiver  36  is operatively connected to controller  13  and welding-type power source  12  and is configured to receive and relay wireless signals from control  50  to controller  13  to process the received wireless data. In this manner, wireless remote control  50  controls operation of the welding-type system  10  and sets or adjusts the various welding-type parameters. 
     As shown in  FIG. 1 , receiver  36  is specially constructed to interconnect to an existing connection port  37  of welding-type system  10 . In addition to interconnecting with receiver  36 , connection port  37  is also configured to engage standard control cables  38  (as shown in  FIG. 2 ) often used in a welding system. As receiver  36  is constructed to engage connection port  37 , older welding-type systems not capable of control via a wireless remote device can be easily modified (i.e., retrofitted) to incorporate receiver  36  and wireless remote control  50  of the current invention. In one embodiment of the current invention, receiver  36  can be constructed to connect to welding-type power source  12  by way of an existing 14-pin connection port  37  located on the front panel  42  of power source  12 . Preferably, receiver  36  is operable with either AC or DC power, and over various control voltages, at least ranging from 5V to 24V. An exemplary control circuit having a wide voltage window is preferred to achieve this functionality. 
     Various means of communication can be used to transmit signals from wireless remote  50  to receiver  36 . In a preferred embodiment, radio control (RC) signals are used. However, other means of communication can include, but are not limited to, radio frequency (RF), cellular digital packet data, high speed circuit switched data, packet data cellular, general packet radio service, radio transmission technology, Bluetooth, IRDA, multi-channel multipoint distribution service, local multipoint distribution service, WiMAX, 802.11 Wi-Fi, infrared, UHF, VHF, and RIM. It is recognized that the mode of communication selected will depend on the specific needs of the welding-type process and on the environment in which the process is being performed in. 
     As shown in  FIG. 1 , it is envisioned that wireless remote control  50  be in the form of a foot pedal control, a handheld control, or a fingertip control; however, such embodiments are not meant to limit the form of the wireless remote control  50  that can be used in the present invention. A wireless remote control  50  in the form of a foot pedal control, fingertip control, or handheld control, can include a switch (not shown) or other similar device thereon that allows an operator to easily adjust and control one or more welding parameters in welding-type system  10 . These controllable welding parameters can include, but are not limited to, current, voltage, inductance, and pulse commands. 
     The specific welding parameter that is controlled by wireless remote control  50  is determined by an operator via a front panel control  42  on power source  12 . Front panel control  42  is of a design well-known in the art, and includes a plurality of adjustors and selectors thereon. The exact mechanisms found on front panel control  42  can vary, but will allow an operator to select the specific welding parameters to be controlled by wireless remote control  50 . 
     As stated above, not only can a welding-type system  10  be designed with the wireless remote control  50  and receiver  36 , but it is also envisioned that existing welding-type systems can be modified with an assembly kit, to allow for wireless remote control of the system. A wireless remote control assembly kit (not shown) can be integrated with an existing welding-type system by operatively connecting receiver  36  with controller  13  of the welding-type power source  12  via an existing connection port  37 . Wireless remote  50  is then configured to communicate with receiver  36 . Receiver  36  is configured to receive and relay wireless signals from control  50  to the controller  13  to process the received wireless data so as to control operation of the welding-type system  10  and set or adjust the various welding-type parameters. 
     As one skilled in the art will readily appreciate, the aforementioned description of welding-type systems not only includes welders, but also includes any system that requires such enclosures and/or high power outputs, such as heating and cutting systems. Those skilled in the art are well acquainted with such welding-type devices, and as used herein, the term is given its ordinary meaning to those skilled in the art of welding and cutting apparatus. 
     Therefore, the present invention, including welding-type systems, is equivalently applicable with any device requiring high power output, including welders, plasma cutters, induction heaters, and the like. Reference to welding power, welding-type power, or welders generally, includes welding, cutting, or heating power. Description of a welding apparatus illustrates just one embodiment in which the present invention may be implemented. The present invention is equivalently applicable with many high power systems, such as cutting, or any similar systems. 
     Therefore, in accordance with one embodiment of the present invention, a welding-type system is disclosed. The welding-type system includes a power source having a controller to regulate welding operations and a welding torch actuated by a trigger and connected to the power source. The system also includes a wireless remote control configured to remotely transmit a signal for controlling a plurality of welding parameters in the welding system, and a receiver remote from the wireless control and configured to receive the signal and allow the controller to regulate at least one of the plurality of welding parameters in response thereto. The receiver is further configured to engage a connection port located on the power source, the connection port configured to engage both the receiver and a control cable. 
     According to another embodiment of the present invention, a wireless remote control kit for retrofitting a welding-type apparatus is provided. The wireless remote control kit includes a wireless control configured to transmit a signal to control a plurality of welding parameters in a welding-type apparatus suitable for producing a welding-type power. The wireless remote control kit further includes a receiver remote from the wireless control and configured to receive and relay the signal to the welding-type apparatus. The receiver is operatively connected to a controller housed in a power source of the welding-type apparatus. 
     According to a further embodiment of the invention, a method for adapting an existing welding-type system for use with a wireless remote control is disclosed. The method includes the steps of connecting a receiver to a welding-type power source by way of an existing control cable connection port, wirelessly transmitting a signal from the wireless remote control indicative of desired operational parameters of the welding-type system, receiving the signal remotely by way of the receiver, and controlling the welding-type system in accordance with data embodied in the received wirelessly transmitted signal. 
     The present invention has been described in the 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.