Abstract:
The invention described herein generally pertains to an apparatus for a welding operation having peripheral attachments combined with welding capability. Particularly, various welders can include powered tools integrated into the welder to expedite welding operations while increasing equipment convenience, reliability, and survivability. In embodiments, a grinder can be built into a welder. In embodiments the welder can be an engine driven welder or hybrid welder.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS AND INCORPORATION BY REFERENCE 
       [0001]    This U.S. patent application is a continuation of and claims the benefit of U.S. provisional patent application 61/876,807 filed on Sep. 12, 2013, which is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    Devices, systems, and methods consistent with the invention relate generally to welding equipment, and more particularly, to combining multiple pieces of welding equipment, and still more particularly to integrating a grinder or other corded accessories with a welding machine. 
       BACKGROUND OF THE INVENTION 
       [0003]    Welding operations are frequently performed with more than a single tool connected to a power supply. In addition to multiple torches or power supplies, a variety of powered and unpowered tools are used to prepare for a future welding operation, guide or improve an ongoing welding operation, or fix or finish a completed welding operation. 
         [0004]    Further, welding operations are frequently conducted under mobile conditions. Worksites change, and entire classes of welders are dedicated to vehicle support or vehicle mounting. Some such welders include engine driven welders. Other welders include battery-powered welders or hybrid welders that utilize multiple sources of power. 
         [0005]    Despite these advances, mobile conditions present a variety of challenges. First, the correct tools must be present at a jobsite. The tools available must also be electrically compatible with power supplies on the jobsite. Electrical compatibility can be influenced by, for example, signal frequency, noise, ground fault circuit interruptor requirements, and others. Even if the tools are locally operable, loss or damage to the tools or cables used to power and operate them remains a risk until the job is complete. 
       SUMMARY OF THE INVENTION 
       [0006]    In accordance with the present invention, there is provided a system for integrating welding and grinding operations. The system can include a motor-driven welder assembly coupled with a motor that is a power source for the welding device to perform a welding operation and a welding grinder including a handle portion and a grinding portion. The system can further include a grinder bay within the motor-driven welder assembly that stows the welding grinder within the motor-driven welder assembly, a a grinding power coupler that provides power from the motor to the welding grinder, and a grinder power cord that couples the welding grinder to the grinding power coupler. 
         [0007]    Further in accordance with the present invention, there is provided a system including a hybrid welding system configured to receive power from a motor and a battery bank, a welding grinder configured to receive power through the hybrid welding system, and a welding grinder compartment of the hybrid welding system configured to store the welding grinder within the hybrid welding system. 
         [0008]    An additional embodiment of a system can include a trailer incorporating a trailer hitch, a trailer frame, and a payload region and an adjustable stand on a front end of the trailer, wherein the adjustable stand is configured to adjust a height of the front end of the trailer. The system includes an engine driven welder secured to the payload region, a motor-driven welder assembly including a motor that is a power source for the engine driven welder to perform a welding operation, and a welding grinder system including at least a handle portion, a control portion, and a grinding portion. A first internal compartment houses the welding grinder system. There is also a grinder power supply that provides power for the grinder from the motor, a grinder cord that couples the welding grinder system to the grinder power supply, a grinder cord spool that stores the grinder cord, a grinder cord stop that prevents stress between a connection of the grinder cord and the grinder cord spool, and a second internal compartment at least partially partitioned from the first internal compartment that houses at least the cord spool. 
         [0009]    These and other objects of this invention will be evident when viewed in light of the drawings, detailed description, and appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above and/or other aspects of the invention will be more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings 
           [0011]    in which: 
           [0012]      FIG. 1  is a diagram illustrating a welding device that includes a motor as a power source; 
           [0013]      FIG. 2  is a diagram illustrating a welding device; 
           [0014]      FIG. 3  is a diagram illustrating a welding device affixed to a trailer for mobility; 
           [0015]      FIGS. 4A and 4B  are diagrams illustrating a welding device; 
           [0016]      FIG. 5  is a diagram of an embodiment of a welder with a built-in grinder; 
           [0017]      FIGS. 6A and 6B  illustrate embodiments including alternative positioning for a built-in grinder for a welder; and 
           [0018]      FIGS. 7A and 7B  illustrate embodiments of a built-in grinder with cutaway portions to depict various aspects of the built-in grinder apparatus. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    Embodiments of the invention will now be described below by reference to the attached figures. The described embodiments are intended to assist the understanding of the invention, and are not intended to limit the scope of the invention in any way. Like reference numerals refer to like elements throughout. 
         [0020]    It is to be appreciated that a power source, as used herein, can be a motor, an engine, a generator, an energy storage device, a battery, a component that creates electrical power, a component that converts electrical power, or a combination thereof. 
         [0021]    Aspects discussed herein are equally applicable to, and can be utilized in, systems and methods related to arc welding, laser welding, brazing, soldering, plasma cutting, waterjet cutting, laser cutting, and any other systems or methods using similar control methodology, without departing from the spirit or scope of the discussed inventions. The embodiments and discussions herein can be incorporated into any such systems and methodologies by those of skill in the art on review of the disclosures. 
         [0022]      FIG. 1  illustrates a welding device  100 . The welding device  100  includes a housing  112  which encloses the internal components of the welding device. Optionally, the welding type device  100  includes a loading eyehook  114  and/or fork recesses  116 . The loading eyehook  114  and the fork recesses  116  facilitate the portability of the welding device  100 . Optionally, the welding-type device  100  could include a handle and/or wheels as a means of device mobility. The housing  112  also includes a plurality of access panels  118 ,  120 . Access panel  118  provides access to a top panel  122  of housing  112  while access panel  120  provides access to a side panel  124  of housing  112 . A similar access panel is available on an opposite side. These access panels  118 ,  120 , provide access to the internal components of the welding device  100  including, for example, an energy storage device (not shown) suitable for providing welding-type power. An end panel  126  includes a louvered opening  128  to allow for air flow through the housing  112 . 
         [0023]    The housing  112  of the welding-type device  100  also houses an internal combustion engine. The engine is evidenced by an exhaust port  130  and a fuel port  132  that protrude through the housing  112 . The exhaust port  130  extends above the top panel  122  of the housing  112  and directs exhaust emissions away from the welding-type device  100 . The fuel port  132  preferably does not extend beyond the top panel  122  or side panel  124 . Such a construction protects the fuel port  132  from damage during transportation and operation of the welding-type device  100 . 
         [0024]    Referring now to  FIG. 2 , a perspective view of a welding apparatus  205  that can be utilized with the subject innovation. Welding apparatus  205  includes a power source  210  that includes a housing  212  enclosing the internal components of power source  210 . As will be described in greater detail below, housing  212  encloses control components  213 . Optionally, welding apparatus  205  includes a handle  214  for transporting the welding system from one location to another. To effectuate the welding process, welding apparatus  205  includes a torch  216  as well as a grounding clamp  218 . Grounding clamp  218  is configured to ground a workpiece  220  to be welded. As is known, when torch  216  is in relative proximity to workpiece  220 , a welding arc or cutting arc, depending upon the particular welding-type device, is produced. Connecting torch  216  and grounding clamp  218  to housing  212  is a pair of cables  222  and  224 , respectively. 
         [0025]    The welding arc or cutting arc is generated by the power source by conditioning raw power received from an interchangeable energy storage device  226 . In a preferred embodiment, energy storage device  226  is a battery. Energy storage device  226  is interchangeable with similarly configured batteries. Specifically, energy storage device  226  is encased in a housing  228 . Housing  228  is securable to the housing of welding apparatus  205  thereby forming welding-type apparatus  205 . Specifically, energy storage device  226  is secured to power source  210  by way of a fastening means  230 . It is contemplated that fastening means  230  may include a clip, locking tab, or other means to allow energy storage device  226  to be repeatedly secured and released from power source  210 . 
         [0026]      FIG. 3  illustrates a trailer  300  incorporating a trailer hitch or hitching device, depicted generally at  301 . The trailer  300  may include a trailer frame  302  and one or more trailer wheels  304  in rotational connection with the trailer frame  302  and may further include a payload region  306  for carrying one or more cargo items, which in an exemplary manner may be a welding power supply  309  or an engine driven welding power supply  309 . The trailer  300  may also include an adjustable stand  310  for adjusting the height of the front end  312  of the trailer  300 . However, any means may be used for raising and/or lowering the front end  312  of the trailer  300 . The trailer hitch  301  may be a generally longitudinal and substantially rigid trailer hitch  301  and may be attached to the frame  302  via fasteners  314 , which may be threaded bolts. 
         [0027]      FIGS. 4A and 48  illustrate a hybrid welding device (herein referred to as a “hybrid welder”). A hybrid welder according to the invention is generally indicated by the number  400  in the drawings. Hybrid welder  400  includes an engine component that runs on fuel from fuel storage  410  allowing the hybrid welder  400  to be portable. It will be appreciated that hybrid welder  400  may also be mounted in a permanent location depending on the application. Hybrid welder  400  generally includes a motor-driven welder assembly  420  having a motor  425  and an energy storage device  430 . Motor  425  may be an internal combustion engine operating on any known fuel including but not limited to gasoline, diesel, ethanol, natural gas, hydrogen, and the like. These examples are not limiting as other motors or fuels may be used. 
         [0028]    The motor  425  and energy storage device  430  may be operated individually or in tandem to provide electricity for the welding operation and any auxiliary operations performed by hybrid welder  400 . For example, individual operation may include operating the motor  425  and supplementing the power from the motor  425  with power from the energy storage device  430  on an as needed basis. Or supplying power from the energy storage device  430  alone when the motor  425  is offline. Tandem operation may also include combining power from motor  425  and energy storage device  430  to obtain a desired power output. According to one aspect of the invention, a welder  400  may be provided with a motor having less power output than ordinarily needed, and energy storage device  430  used to supplement the power output to raise it to the desired power output level. In an embodiment, a motor with no more than 19 kW (25 hp) output may be selected and supplemented with six 12 volt batteries. Other combinations of motor output may be used and supplemented with more or less power from energy storage device. The above example, therefore, is not limiting. 
         [0029]    Energy storage device  430  may be any alternative power source including a secondary generator, kinetic energy recovery system, or, as shown, one or more batteries  431 . In an embodiment, six 12 volt batteries  431  are wired in series to provide power in connection with motor-driven welder assembly  420 . Batteries  431  shown are lead acid batteries. Other types of batteries may be used including but not limited to NiCd, molten salt, NiZn, NiMH, Li-ion, gel, dry cell, absorbed glass mat, and the like. 
         [0030]    In embodiments, hybrid welder  400  can include a switch component for switching between power from motor  425  and energy storage device  430 . In embodiments, switches can actuate one or both of motor  425  and energy storage device  430  simultaneously. In alternative or complementary embodiments, control circuitry can be used to effect switching manually or automatically. 
         [0031]    Embodiments for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time of the filing of this patent application. The examples and figures are illustrative only and not meant to limit the invention which is measured by the scope and spirit of the claims. Referring now to the drawings, wherein the showings are for the purpose of illustrating an exemplary embodiment of the invention only and not for the purpose of limiting same,  FIGS. 5-8  illustrate a schematic block diagram of a welding device, and in particular, an engine driven welding device as discussed in  FIGS. 1-4 . 
         [0032]      FIG. 5  shows an embodiment of a welder  500  including built-in grinder system  520 . Built-in grinder system  520  includes grinder  521 , which can be stowed in recess  529 . Grinder  521  can include a handle portion and a grinding portion. In some embodiments, grinder  521  is detachable from built-in grinder system  520 , in either a cord-tethered configuration or wholly wireless. In alternative embodiments, grinder  521  remains at least partially fixed to at least a portion of built-in grinder system  520 . Grinder  521  can be a hand-held grinder, or include various restraints or assists to manage its motion and operation. The handle portion can be one or more portions designed for operator handling, and can include one or more controls (e.g., a trigger) to initiate or modify grinding operations. The grinding portion can include portions that contact the workpiece, as well as shields or other components designed to aid in ease of use or safety. In embodiments, at least a part of the grinding portion can be exchanged or swapped. 
         [0033]    When grinder  521  is stowed in recess  529 , access panel  530  can be closed. In embodiments, access panel  530  is flat, and creates a flush closure matching the contours of welder  500  when closed. In other embodiments, access panel  530  can be curved, 3-dimensional, or include a “jog-out”, increasing the closed volume of recess  529  to accommodate the specific geometry of grinder  521 . In still other alternative embodiments, access panel  530  can include a hole that allows at least a portion of built-in grinder system  520  to protrude through access panel  530  when access panel  530  is in a closed state. 
         [0034]    Grinder  521  is supported by base  522 . In embodiments, base  522  can extend outward from recess  529  to permit easy access to grinder  521  and a secure resting position for grinder  521  when not in use. In embodiments where base  522  can extend outward using support system  523 . Support system  523  can include drawer-like rails which telescope or nest when transitioning between an open or closed state. In embodiments, base  522  can be extended or retracted through other mechanisms (e.g., swinging out or in) and can be supported through other mechanisms (e.g., hinges, support cables, legs, stops). In embodiments, base  522  can be cantilevered when extended outward, and support system  523  does not extend beyond the outer edge of welder  500 . 
         [0035]    Grinder  521  is coupled with retractable cord  524 . Retractable cord  524  provides electrical power to grinder  521  for operation. In embodiments, retractable cord  524  can be reinforced to resist damage (e.g., fraying, cutting) and permit use of retractable cord  524  as a tether for grinder  521 . Retractable cord  524  can pass through cord aperture  525  to a compartment partitioned from recess  529  where the cord can be kept. Retractable cord  524  can have attached thereto a cord stop (not pictured in  FIG. 5 ) that contacts cord aperture  525  or another component to prevent retractable cord  524  from being overextended, damaged, or disconnected from welder  500  or other coupled components. 
         [0036]    While built-in grinder system  520  is shown oriented in a particular area of welder  500 , those of skill in the art will appreciate how this orientation is for illustrative purposes only, and that the particular positioning illustrated is only one of many possible configurations under the disclosures here. Further, it is understood that some embodiments of welders may not permit integration of built-in grinder system  520 , due to the location of internal components. Nonetheless, at least one embodiment of welder can be configured to integrate built-in grinder system  520  as illustrated, and  FIG. 5  can provide illustrative detail for integration in other embodiments. 
         [0037]    Further, while grinder  521  is shown with retractable cord  524 , it is understood that, in alternative embodiments, retractable cord  524  need not be a component of built-in grinder system  520 , and grinder  521  can be a cordless grinder with a self-contained battery. In some such embodiments, grinder  521  can include a recharging port that mates with a similar port in base  522 . In this way, the self-contained battery of a cordless grinder  521  can be recharged using power from welder  500 . 
         [0038]      FIGS. 6A and 6B  illustrate embodiments of possible placements of a built-in grinder in relation to various welding components.  FIG. 6A  illustrates a hybrid welder  600  with its outer case removed, and  FIG. 6B  shows an energy storage apparatus  650  for use with hybrid welder  600 . 
         [0039]    While  FIGS. 6A and 6B  depict built-in grinding systems  620  and  620 ′, respectively, it is understood that when hybrid welder  600  and energy storage apparatus  650  are used in conjunction, only one of grinding systems  620  and  620 ′ will be included. Thus, in some embodiments of a hybrid welding system using hybrid welder  600  and energy storage apparatus  650 , only one of built-in grinding system  620  and built-in grinding system  620 ′ will be present. Nonetheless, alternative embodiments can include two or more of built-in grinding system  620 , built-in grinding system  620 ′, and another tool integrated in a fashion similar to one of built-in grinding systems  620  and  620 ′. 
         [0040]      FIG. 6A  shows hybrid welder  600  decoupled from energy storage apparatus  650  with its motor and fuel storage exposed. Built-in grinding system  620  can be integrated in a void between the motor and fuel storage, or in another position. As illustrated between motor and fuel storage, built-in grinding system  620  can be surrounded by or include heat-resistant materials intended to insulate the grinder from motor heat, or conduct heat away from the built-in grinding system  620 . 
         [0041]    Built-in grinding system  620  can include grinder  621 , base  622 , and base supports  623 . Base  622  may extend out of or retract into the space between the motor and fuel storage to improve access to grinder  621  and/or provide a “table” on which to replace grinder  621 . Base  622  can be supported or retained in one or both of extended and retracted positions by base supports  623 . 
         [0042]    Grinder  621  is powered using electricity provided through retractable cord  624 . Retractable cord  624  is stored about cord spool  627 , which can be manually wound to spool or unspool retractable cord  624 , or be biased (e.g., spring-loaded) to automatically spool slack in retractable cord  624 . In embodiments, retractable cord  624  need not pass through a cord aperture, and cord spool  627  can be disposed in a position with no physical separation from other components of built-in grinding system  620 . 
         [0043]      FIG. 6B  shows energy storage apparatus  650  (e.g., battery bank) having built-in grinding system  620 ′. Built-in grinding system  620 ′ includes cordless grinder  621 ′. Cordless grinder  621 ′ includes grinder charging port  640 , which is configured to couple with base charging port  641  on base  622 ′. In this way, an internal battery for cordless grinder  621 ′ can be recharged when cordless grinder  621 ′ is on base  622 ′. Base  622 ′ can be restrained or moved about by way of base supports  623 ′. In some embodiments, built-in grinding system  620 ′ can be placed in a space which may otherwise house a battery or other portion of energy storage apparatus  650 . 
         [0044]    Bases  622  and  622 ′ can include strap, clip, retainer, or other securing member (not pictured) to secure grinder  621 / 621 ′ when engaged. When a securing member is engaged, hybrid welder  600  and/or energy storage apparatus  650  can be moved without shifting of grinder  621 / 621 ′, and grinder  621 / 621 ′ is secure and prevented from falling off base  622 / 622 ′. 
         [0045]      FIGS. 7A and 7B  illustrate cutaway views of welding system  700  incorporating built-in grinder system  720 . Welding system  700  includes engine-driven welder  710 , which is operatively coupled to engine  740 . Engine  740  is used to generate at least a portion of power utilized by engine driven welder  710 . 
         [0046]    In addition to components utilized with welding tools, engine driven welder  710  includes grinder opening  729  (or grinder bay), which stores grinder  721  and associated components. Grinder opening  729  is exposed or enclosed depending on the position of grinder door  730 . Grinder door  730  can be hingedly attached or fold in an outward or inward direction. In embodiments, grinder door  730  can slide along rails to be opened outside engine driven welder  710 , or can slide into a compartment of engine driven welder  710 . In hinged and sliding embodiments, grinder door  730  may include multiple partitions (e.g., hingedly connected) that allow the door to assume curvature otherwise change its shape during opening or closing. Grinder door  730  can include door lock  731 , which can attach to one of grinder locks  732  and  733  to secure grinder door  730  in an open or closed position. In some embodiments, door lock  731  can include a lock to provide security and prevent unauthorized use or removal of grinder  721 . 
         [0047]    Grinder  721  is electrically powered by retractable cord  724 . Retractable cord  724  passes through a partition via cord aperture  725 , whereafter spool  727  (or another cord-retention component) retains excess cord not needed to move the grinder to a position where it is utilized. Retractable cord  724  can be used in combination with overextension preventer  726 , which is fixed to at least one portion of retractable cord  724  and stops in contact with cord aperture  725  or another component to prevent retractable cord  724  from being overextended and separating from spool  727  or power coupler  728 . Positions or locations where overextension would strain or damage the connections of retractable cord  724  can be referred to as maximum extension positions. A distal cord end operatively attaches with power coupler  728 , which routes appropriate electrical power to retractable cord  724  to power grinder  721 . In embodiments, power coupler  728  can include a converter, inverter, fuse, surge protector, or other components that prevent excess electrical power from being routed to and possibly damaging grinder  721 . 
         [0048]    Grinder  721  can rest on base  722 . As shown in at least  FIG. 7A , base  722  includes at least a stowed position and a usage position. Base  722  can slide, roll, or otherwise be moved out of grinder opening  729  to improve access and function of built-in grinder system  720 . Base tracks  723  can support base  722  in one or both of the stowed position and usage position. In some embodiments, base  722  can be machined, molded, or otherwise shaped to accommodate grinder  721  placed on base  722  in one or more positions. 
         [0049]    In some embodiments, grinder  721  can be associated with control module  750 . Control module  750  can send control signals to grinder controller  751  to provide grinding parameters for operations. For example, a particular grinding operation can be optimized using a particular range of speeds (e.g., 500-700 rotations per minute). In embodiments, control module  750  can provide a signal to grinder controller  751  that limits grinder  721  speeds to the identified range. Other parameters can include power (e.g., power level), torque, braking, automatic shutoff, et cetera. Control module  750  and grinder controller  751  can communicate by wired or wireless techniques. In embodiments control module  750  may be communicatively connected to retractable cord  724 , and may use retractable cord  724  to send or receive signals with grinder controller  751 . In specific embodiments, retractable cord  724  can be a combined cable including both a power cable for carrying electrical power and a communication cable for carrying information between components. In at least one embodiment, control module  750  and grinder controller  751  are a single component. 
         [0050]    In some embodiments, control module  750  can select a grinder power supply and/or modify a grinder power parameter. For example, power received through power coupler  728  can be, prior to actuation of grinder  721 , power configured to support welding or another operation having different requirements or constraints than those of grinder  721 . Upon action related to grinder  721  (e.g., actuation by trigger, removal from base  722 , extension of retractable cord  724 , movement of base  722  with reference to base supports  723 , opening of grinder door  730 ), control module  750  can check the status of power being supplied to engine-driven welder  710  and via power coupler  728  to ensure supplied power is compatible (e.g., voltage, alternating or direct current, current level, polarity) with grinder  721 . Alternatively, action related to grinder  721  can automatically toggle to an appropriate power setting. Further, in embodiments where multiple energy sources are available (e.g., engine-driven welder with hybrid battery capability) control module  750  can evaluate the stability and longevity of power sources to select which to employ (e.g., prefer engine  740  when available, switch from batteries when levels low, prioritize welder user of electricity) when operating grinder  721 . 
         [0051]    While embodiments discussed herein have been related to the systems and methods discussed above, these embodiments are intended to be exemplary and are not intended to limit the applicability of these embodiments to only those discussions set forth herein. The control systems and methodologies discussed herein are equally applicable to, and can be utilized in, systems and methods related to arc welding, laser welding, brazing, soldering, plasma cutting, waterjet cutting, laser cutting, and any other systems or methods using similar control methodology, without departing from the spirit of scope of the above discussed inventions. The embodiments and discussions herein can be readily incorporated into any of these systems and methodologies by those of skill in the art. By way of example and not limitation, a power supply as used herein (e.g., welding power supply, among others) can be a power supply for a device that performs welding, arc welding, laser welding, brazing, soldering, plasma cutting, waterjet cutting, laser cutting, among others. Thus, one of sound engineering and judgment can choose power supplies other than a welding power supply departing from the intended scope of coverage of the embodiments of the subject invention. Other variations, related and unrelated to those briefly described above, will be understood by those of skill in the art upon review of the disclosures herein.