Patent Description:
Conventional welding systems may be capable of operating in a single mode, such as an arc welding mode or a gouging mode. Thus, operators who wish to perform both wire welding and gouging at a given jobsite require two separate power sources, and may have to leave the jobsite to change settings of the welding power supply and/or the welding wire feeder in order to switch between modes.

In this regard, the operator may benefit from systems and methods that provide systems or methods to switch between modes without leaving the jobsite.

According to the present invention, a welding system is defined in claim <NUM>.

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 present disclosure is directed to systems and methods for automatically activating or deactivating a gouging torch. In particular, the disclosed systems and methods activate and/or deactivate a gouging torch based on a valve operation selection. For example, for welding power supplies and/or welding wire feeders configured to operate both wire welding processes (e.g., gas metal arc welding (GMAW), flux-cored arc welding (FCAW), shielded metal arc welding (SMAW)) as well as gouging (e.g., Carbon Arc Cutting-Air (CAC-A)), a valve can be integrated with a gouging torch, which can be adjusted to allow or arrest the flow of compressed air to the gouging torch. In response, the welding power source and/or welding wire feeder automatically changes one or more output characteristics (e.g., wire feed speed, power source settings, etc.), to switch between a wire welding process and a gouging process without requiring the operator to interact with either the welding power source or welding wire feeder.

Thus, the disclosed systems and methods employ a selector, which may be connected to a valve on the torch, to make a process selection, which causes the welding power supply and/or the welding wire feeder to adjust one or more output characteristics in response. The system may include separate cabling to each of the wire welding torch and the gouging torch (e.g., from the welding power supply and/or the welding wire feeder), as well as a separate compressed air line to the gouging torch.

Conventionally, operators who wish to perform both wire welding and gouging at a given jobsite have limited options. For example, two separate power sources can be used, one for each process. The operator may walk to the welding power supply and/or the welding wire feeder in order to change settings. In some examples, the operator may use a Y-cord on the welding circuit to connect both the wire feeder and gouge torch. However, given that each process requires specific outputs, one or both of the processes experience degraded performance when operating on the settings of the other (e.g., employing a constant voltage (CV) process for gouging translates into lower performance in comparison to a dedicated constant current (CC) process)).

In disclosed systems and methods, a sensor (e.g., an air flow and/or pressure sensor) monitors air to a gouging torch. Changes associated with the air to the gouging torch (e.g., a change in air flow rate or pressure, and/or a value of the air flow rate and/or the pressure with respect to one or more thresholds) can indicate whether the valve has been moved to select a gouging process or a wire welding process. In response, the control circuitry (in the welding power supply, the wire feeder, or both) can adjust one or more output parameters (e.g., power, voltage, current, wire feed speed, polarity, etc.) to provide output suitable for the selected process.

Advantageously, the discloses systems and methods allows the operator to remain in position at a joint to perform both welding and gouging operations without the need to disconnect cables or torches, and/or walk to the wire feeder and/or the welding power supply to transition between operations. Further, the use of valves, sensors, contactors, and/or software solutions ensures that the gouging torch is de-energized when not in use.

In disclosed examples, a welding system includes a power supply to operate in an arc welding mode or a gouging mode: a compressed air flow detection sensor configured to measure a flow rate or a pressure of compressed air to a torch; and a control circuitry configured to: receive signals from the compressed air flow detection sensor corresponding to the flow rate; control the power supply to operate in a gouging mode when the flow rate or the pressure has exceeded a first threshold flow rate or pressure; and control the power supply to operate in an arc welding mode when the flow rate or the pressure has gone below a second threshold flow rate or pressure.

In some examples, the torch comprises a selector to indicate an operating mode between the arc welding mode or the gouging mode. In examples, the selector is a valve to control flow of compressed air to the torch. In some examples, an interlock circuit configured to: close a gouging circuit and open an arc welding circuit in the gouging mode; and close the arc welding circuit and open the gouging circuit in the arc welding mode.

In examples, the interlock is a contactor, the control circuitry further configured to activate the contactor to open the gouging circuit in response to the welding torch trigger pull. In some examples, a wire feeder attached to the power source and cables from wire feeder to each torch, wherein compressed air is routed through the wire feeder and to the torch.

In examples, the compressed air flow detection sensor is located in the wire feeder and configured to transmit signals corresponding to the flow rate or the pressure to the control circuitry. In some examples, the compressed air flow detection sensor is located in the power supply and configured to transmit signals corresponding to the flow rate or the pressure to the control circuitry.

In examples, a welding cable connecting the torch to the wire feeder, the welding cable to convey one or more of arc welding power, gouging power, compressed air, electrode wire, shielding gas, or control signals. In some examples, wherein the control circuitry is further configured to control the wire feeder to stop electrode wire from advancing from the wire feeder to the torch in the gouging mode.

In examples, the control circuitry is further configured to adjust one or more output characteristics according to a gouging profile in response to activation of the gouging mode. In some examples, the one or more output characteristics comprises one or more of polarity, a voltage, a current, a power, a wire feed speed, or a combination thereof. In examples, the control circuitry is further configured to adjust one or more output characteristics according to an arc welding profile in response to activation of the arc welding mode.

In some examples, the sensor sends a signal to the control circuitry in response to the air flow or pressure exceeding the first threshold flow rate or pressure or the second threshold flow rate or pressure.

The term "welding-type system," as used herein, includes any device capable of supplying power suitable for welding, plasma cutting, induction heating, Carbon Arc Cutting-Air (e.g., CAC-A, or gouging), and/or hot wire welding/preheating (including laser welding and laser cladding), including inverters, converters, choppers, resonant power supplies, quasi-resonant power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.

As used herein, the term "welding-type power" refers to power suitable for welding, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding).

As used herein, the term "welding-type power supply" and/or "power supply" refers to any device capable of, when power is applied thereto, supplying welding, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding) power, including but not limited to inverters, converters, resonant power supplies, quasi-resonant power supplies, and the like, as well as control circuitry and other ancillary circuitry associated therewith. The term can include engine driven power supplies, energy storage devices, and/or circuitry and/or connections to draw power from a variety of external power sources.

As used herein, the term "wire feeder" includes the motor or mechanism that drives the wire, the mounting for the wire, and controls related thereto, and associated hardware and software.

As used herein, the term "torch," "welding torch," "welding tool" or "welding-type tool" refers to a device configured to be manipulated to perform a welding-related task, and can include a hand-held welding torch, robotic welding torch, gun, gouging tool, cutting tool, or other device used to implement a welding process.

As used herein, a "circuit," or "circuitry," includes any analog and/or digital components, power and/or control elements, such as a microprocessor, digital signal processor (DSP), software, and the like, discrete and/or integrated components, or portions and/or combinations thereof.

The terms "control circuit," "control circuitry," and/or "controller," as used herein, may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), and/or other logic circuitry, and/or associated software, hardware, and/or firmware. Control circuits or control circuitry may be located on one or more circuit boards that form part or all of a controller, and are used to control a welding process, a device such as a power source or wire feeder, and/or any other type of welding-related system.

As used herein, the term "memory" includes volatile and non-volatile memory devices and/or other storage device.

As used herein, the term "energy storage device" is any device that stores energy, such as, for example, a battery, a supercapacitor, etc..

As used herein, the term "welding mode," "welding process," "welding-type process" or "welding operation" refers to the type of process or output used, such as current-controlled (CC), voltage-controlled (CV), pulsed, gas metal arc welding (GMAW), flux-cored arc welding (FCAW), gas tungsten arc welding (GTAW, e.g., TIG), shielded metal arc welding (SMAW), spray, short circuit, CAC-A, gouging process, plasma cutting, cutting process, and/or any other type of welding process.

As used herein, the term "welding program" or "weld program" includes at least a set of welding parameters for controlling a weld. A welding program may further include other software, algorithms, processes, or other logic to control one or more welding-type devices to perform a weld.

As used herein, "power conversion circuitry" and/or "power conversion circuits" refer to circuitry and/or electrical components that convert electrical power from one or more first forms (e.g., power output by a generator) to one or more second forms having any combination of voltage, current, frequency, and/or response characteristics. The power conversion circuitry may include safety circuitry, output selection circuitry, measurement and/or control circuitry, and/or any other circuits to provide appropriate features.

As used herein, the term "boost converter" is a converter used in a circuit that boosts a voltage. For example, a boost converter can be a type of step-up converter, such as a DC-to-DC power converter that steps up voltage while stepping down current from its input (e.g., from the energy storage device) to its output (e.g., a load and/or attached power bus). It is a type of switched mode power supply.

As used herein, the term "buck converter" (e.g., a step-down converter) refers to a power converter which steps down voltage (e.g., while stepping up current) from its input to its output.

As used herein, the terms "first" and "second" may be used to enumerate different components or elements of the same type, and do not necessarily imply any particular order.

<FIG> illustrates an example welding system <NUM> for automatically activating a gouging torch. As shown in the welding system of <FIG>, a power supply <NUM> and a wire feeder <NUM> are coupled via one or more conductors or conduits to share power, data, and/or other consumables. In the illustrated example, the power supply <NUM> may be separate from the wire feeder <NUM>, such that the wire feeder may be positioned at some distance from the power supply near a welding location. However, in some examples the wire feeder may be integrated with the power supply <NUM>. In examples in which the wire feeder <NUM> is separate from the power supply <NUM>, terminals are typically provided on the power supply and on the wire feeder <NUM> to allow the conductors or conduits to be coupled to the systems so as to allow for power and/or gas to be provided to the wire feeder <NUM> and/or a tool from the power supply <NUM>, and to allow data to be exchanged between the two devices (e.g., between control circuitry <NUM>, <NUM>). In some examples, a cable <NUM> can provide power from the power supply <NUM> to the wire feeder <NUM>, and a cable <NUM> can provide data to or from the wire feeder <NUM>. In some examples, a single cable can be used to provide both power and data between the power supply <NUM> and the wire feeder <NUM>.

The system <NUM> is configured to provide wire, power and shielding gas to one or more welding tools, such as gouging torch <NUM> and/or welding torch <NUM>. The welding torch <NUM> may be one of many different types, and may allow for the feed of a welding wire <NUM> (e.g., an electrode wire) from a wire drive <NUM> and/or gas from a shielding gas source <NUM> via a gas valve <NUM> and tube <NUM> to the welding torch <NUM>. The welding torch <NUM> can then travel to a location adjacent to a workpiece <NUM> to perform a welding operation. The welding torch <NUM> may be activated by a trigger <NUM>, which can send signals to the control circuitry <NUM> to activate wire drive <NUM> and/or supplemental wire feeder <NUM>. A second conductor <NUM> is run to the welding workpiece <NUM> so as to complete an electrical circuit between the power supply <NUM> and/or the wire feeder <NUM> and the workpiece <NUM>, such as via a clamp <NUM>.

The gouging torch <NUM> includes a selector <NUM> (e.g., a mechanical and/or electronic switch) to control flow of air, such as from a compressed air source <NUM>. Although illustrated as located on torch <NUM>, the selector <NUM> (and/or valve <NUM>) may be located on the wire feeder <NUM>, the power supply <NUM>, and/or along the length of the tubing that provides air flow to the torch <NUM>. The compressed air source <NUM> (e.g., an air compressor) may be connected to one or more of the control circuitry <NUM>, <NUM>, and may draw power from the power conversion circuit <NUM> and/or an alternative power source (e.g., an energy storage device, mains power, etc.).

The control circuit <NUM> is coupled to power conversion circuit <NUM>. This power conversion circuit <NUM> is adapted to create the output power, such as pulsed waveforms applied to the welding wire <NUM> at the tool <NUM>. Various power conversion circuits may be employed, including choppers, boost circuit, buck circuit, inverters, converters, and so forth. The power conversion circuit <NUM> is coupled to a source of electrical power, such that the power applied to the power conversion circuit <NUM> may originate in the power grid, although other sources of power may also be used, such as power generated by an engine-driven generator, batteries, fuel cells or other alternative sources. The power supply illustrated in <FIG> may also include an interface circuit <NUM> configured to allow the control circuit <NUM> to exchange signals with the wire feeder <NUM>, the torches <NUM>, <NUM>, and/or a remote control device (e.g., via wired connection and/or wirelessly).

In order to activate a gouging operation, the operator employs selector <NUM> to indicate a gouging mode, such that air flow from the compressed air source <NUM> to the torch <NUM> (e.g., via air sensor <NUM>), drawing power from power conversion circuitry <NUM> (and/or power conversion circuitry <NUM>). In disclosed examples, as the selector <NUM> is employed to indicate a gouging mode, the selector <NUM> opens a valve <NUM> to allow air to flow from the compressed air source <NUM> to the torch <NUM>. Air sensor <NUM> measures the air flow (e.g., a change in the air flow or pressure, and/or an absolute air flow or pressure value), and the information is transmitted to the control circuitry <NUM> (and/or control circuitry <NUM>), which determines activation of a gouging mode based on the selection. In some additional or alternative examples, the selector <NUM> includes one or more circuits, such as a sensor and/or transceiver, configured to transmit a signal to the control circuitry directly. Although illustrated as located within the wire feeder <NUM>, additional or alternative air sensors may be located in the torch <NUM> body and/or along a length of the tube bringing air to the torch <NUM>.

Upon determining the selection of a gouging mode, the control circuitry <NUM> controls a switch <NUM> (e.g., a contactor, a switch, a high amperage relay, solid-state device, an interlock, etc.) to close a circuit to provide power from power conversion circuity <NUM> to the torch <NUM>. Additionally, the control circuitry <NUM> controls switch <NUM> to open a circuit to prevent power from flowing to the welding torch <NUM>. In examples, if a gouging process has been initiated, but the torch <NUM> has not been activated (e.g., the selector <NUM> has not been activated, etc.) within a given period of time, the control circuitry <NUM> may automatically terminate the gouging mode. This may include opening the switch <NUM>, closing one or more valves of compressed air, and/or activating a welding mode. In some additional or alternative examples, the gouging torch <NUM> includes a trigger <NUM>, which can be employed to activate the torch <NUM>.

The selector <NUM> can be employed to close the valve <NUM> and/or otherwise indicate the gouging operation has concluded. Signals are transmitted to the control circuit <NUM> (e.g., from the air sensor <NUM> and/or valve <NUM>) that the gouging operation has ended, which then controls switch <NUM> to open the circuit to the torch <NUM>, thereby preventing power from flowing to the torch <NUM>. In some examples, the control circuitry <NUM> may automatically command switch <NUM> to close, thereby providing power to the welding torch <NUM> in preparation for a welding operation. In some examples, application of the trigger <NUM> of welding torch <NUM> indicates to the control circuitry <NUM> that a welding operation is selected, and closes the switch <NUM> (and/or opens the switch <NUM>) to implement a welding operation. Pulling trigger <NUM> may also cause a valve controlling flow of the compressed air to close (e.g., valve <NUM>, and/or a valve on compressed air source <NUM>).

when a measured and/or detected flow rate exceeds a first threshold, the control circuitry transitions the system to a gouge mode configuration. When a flow rate falls below a second, lower threshold, the control circuitry controls the system to exit the gouge mode. Upon exit of the gouge mode, the system can return to a welding mode or, in some examples, turn off or enter an idle mode.

In some examples, activating the torch <NUM> (e.g., a MIG torch, such as by a pull of trigger <NUM>) can cause the system to exit the gouge mode. In additional or alternative examples, a timer can determine if a predetermined amount of time has passed without gouge current being detected.

In some examples, the system can maintain a default state when the gouge and/or welding modes have not been selected and/or are not active. For instance, the control circuitry may determine there is not air flow (e.g., gouge mode has not been selected/activated), and/or the trigger <NUM> has not been pressed (or other action, such as a selection of welding mode) to indicate welding mode has been activated.

In an example idle state, both contactors <NUM> and <NUM> would be open. Although in an idle state, the system configuration may remain in the previously employed mode (e.g., gouge or welding modes). Thus, an operator could turn off the air flow (e.g., via selector <NUM> and/or valve <NUM>) when a gouge rod has been exhausted, thereby de-energizing the gouge torch and allowing the operator to change the rod without the electrode being live. Once the rod has been replaced, the operator could then turn the air back on, triggering the system to enter a gouging mode, which would close contactor <NUM> and provide power to torch <NUM> to continue a gouging process.

In some examples, de-selection of a gouging mode (or closing valve <NUM>) would not cause the system to transition to a welding mode. For instance, transitioning to a welding mode may result in a number of output parameters to change (such as changing polarity on the power source), even as the operator may desire a return to the gouging mode, thus avoiding delays due to changing settings unnecessarily. Thus, even in the absence of airflow, the system may not return to a welding mode unless or until the trigger <NUM> is activated. In some examples, the system may be configured to transition between operating modes in response to a timeout (e.g., transitioning to idle mode after a given period of time).

In examples, the power supply <NUM> delivers a power output to one or more of the torch <NUM> or the torch <NUM> without employing any switch or contactor. In such an example, power regulation is governed by the control circuitry <NUM>, <NUM> and/or the power conversion circuitry <NUM>, <NUM>. In some examples, a single cable <NUM> (e.g., a multi-functional cable) is connected to the power supply <NUM> or the wire feeder <NUM>. The cable <NUM> may include a coupler <NUM> configured to removably connect to each torch <NUM>, <NUM>. In such an example, the selector <NUM> may be located on the coupler, along the cable (e.g., a remote control), the torch, the wire feeder, and/or the power supply.

The control circuitry <NUM> and/or control circuitry <NUM> adjusts one or more operational characteristics to implement the selected gouging mode or one or more welding modes. For example, process instructions for the arc welding and/or gouging operation can be provided as a weld sequence program, such as stored on a memory accessible to a processor/control circuitry <NUM> associated with the power supply <NUM> (and/or control circuitry <NUM>). In such a case, the sequencer can employ stored information (e.g., associated with a desired operating mode, including historical data), and/or customizable information input by an operator (e.g., via an interface).

For example, a memory device may store processor executable instructions (e.g., firmware or software) for the control circuitry <NUM> or control circuitry <NUM> to execute. In addition, one or more control regimes for various welding processes (e.g., metal inert gas (MIG) or a gas tungsten arc welding (GTAW) welding process, plasma cutting, etc.), along with associated settings and parameters, may be stored in the memory device, along with code configured to provide a specific output (e.g., output power, power characteristics, change in polarity, initiate wire feed or set wire feeder speed, enable gas flow, wire feeder direction, travel speed, process mode, deposition path, deposition sequence, torch angle, etc.) during operation. One or more lists or look up tables may be provided, and/or network connections to various databases available to inform decision-making, such as to access preferred output parameters, to store updated parameter settings, etc..

For example, implementing a gouging process may include a change in polarity at the power supply <NUM> (e.g., via conversion circuitry <NUM>). Thus, the information associated with activation of a gouging mode can be used to control operation of the system to change the polarity and facilitate proper adjustment of the operating characteristics in response to a selected operational mode, such as by controlling a power output from the power supply <NUM>, wire feeder motors in wire drive <NUM>, etc. In this manner, the system and/or the control circuit <NUM> controls the operational mode by adjusting one or more operational characteristics of the system to correspond to a gouging mode or one or more welding modes.

Compressed air may be routed from the compressed air source <NUM> through the power supply <NUM>. The power supply <NUM> may include an air sensor <NUM>, where the flow rate and/or pressure would be detected. The compressed air can then be conveyed to the torch <NUM> via alternative tubing <NUM>. Signals from the air sensor <NUM> could activate and/or deactivate the gouging mode, in a manner similar to air sensor <NUM>.

The system <NUM> is configured for data settings to be selected by the operator and/or a welding sequence, such as via an operator interface <NUM> provided on the power supply <NUM>. The operator interface <NUM> will typically be incorporated into a front faceplate of the power supply <NUM>, and may allow for selection of settings such as the weld process, the type of wire to be used, voltage and current settings, and so forth. In particular, the system is configured to allow for welding with various steels, aluminums, or other welding wire that is channeled through the welding torch <NUM>. These weld settings are communicated to a control circuit <NUM> within the power supply. The control circuit <NUM> may be in communication with various components of the welding power supply <NUM>, as well as a control circuit <NUM> located in the wire feeder <NUM>. In some examples, the wire feeder <NUM> incorporates an interface circuit, to receive inputs from a user and/or remote system.

<FIG> shows a flowchart representative of example machine readable instructions <NUM> which may be executed by the control circuitry <NUM> or <NUM> of <FIG> for automatically activating or deactivating a gouging torch. At block <NUM>, the system is operating in a welding mode (such as via a selector (e.g., selector <NUM>). At block <NUM>, a signal corresponding to a change in flow rate or pressure (or an absolute value of flow rate or pressure) is received (e.g., from air sensor <NUM>, air sensor <NUM>, and/or the selector <NUM>).

At block <NUM>, the change or value of the flow rate or pressure is compared to one or more threshold flow rates or pressures (e.g., stored in memory of control circuitry <NUM>, <NUM>). If the change or value does not exceed the first threshold flow rate or pressure at block <NUM>, the method proceeds to block <NUM> to monitor for a welding trigger (or other selection of a welding mode). If the welding trigger has activated the welding mode, the method proceeds to block <NUM> to operate in the welding mode. If the welding trigger has not activated the welding mode, the method proceeds to block <NUM> to continue to monitor for a signal corresponding to a flow rate or pressure.

In some examples, the process identified in blocks <NUM> to <NUM> corresponds to an idle state as disclosed herein, as represented in block <NUM>. For instance, the system can maintain a default state when the gouge and/or welding modes have not been selected and/or are not active. In an example idle state, both contactors <NUM> and <NUM> would be open.

If the change or value exceeds the first threshold flow rate or pressure at block <NUM>, the control circuitry controls the power supply to operate in a gouging mode at block <NUM>, such as by changing one or more operating parameters according to effect a gouging process. At block <NUM>, the control circuitry closes the gouging contactor (e.g., contactor <NUM>) to close the gouging circuit. At block <NUM>, the gouging mode is active, and the control circuitry monitors one or more output parameters. For instance, at block <NUM>, if output current exceeds a given threshold (e.g., corresponding to a gouging process), the method continues to operate in gouging mode and monitors the output parameters in a loop.

If the output current does not exceed the given current threshold, the method proceeds to block <NUM> to determine whether a welding trigger has been pulled (and/or other activation technique). If welding has been activated, the method continues to block <NUM> to open the gouging contactor. At block <NUM>, the control circuitry changes operating parameters to effect a welding operation in block <NUM>.

If a welding has not been activated, the method proceeds to block <NUM>, where the flow rate or pressure is compared against one or more thresholds. If a flow rate falls below a second threshold (e.g., lower than the first threshold), the control circuit exits the gouge mode, including opening the gouging contactor and gouging circuit in bock <NUM>. Upon exit of the gouge mode, the method returns to a welding mode in block <NUM>. In some examples, the control circuitry may turn off the system and/or enter an idle state, as disclosed herein.

If the flow rate does not fall below the second threshold, the method proceeds to block <NUM> to activate a timer. If a predetermined amount of time has passed without gouge current being detected, the method continues to block <NUM> to deactivate the gouging mode. If the predetermined amount of time has not passed before gouging current is detected, the method returns to block <NUM> to operate in the gouging mode.

Example implementations include an application specific integrated circuit and/or a programmable control circuit.

Claim 1:
A welding system (<NUM>) comprising:
a power supply (<NUM>) to operate in an arc welding mode or a gouging mode:
characterised in that the welding system comprises a compressed air flow detection sensor (<NUM>) configured to measure a flow rate or a pressure of compressed air to a torch (<NUM>,<NUM>); and
a control circuitry (<NUM>,<NUM>) configured to:
receive signals from the compressed air flow detection sensor (<NUM>) corresponding to the flow rate or the pressure;
control the power supply (<NUM>) to operate in a gouging mode when the flow rate or the pressure has exceeded a first threshold flow rate or pressure; and
control the power supply (<NUM>) to operate in an arc welding mode when the flow rate or the pressure has gone below a second threshold flow rate or pressure.