Patent Description:
In some welding applications, a welding wire feeder may be used to feed welding wire from a wire spool to a welding torch for a welding operation. In some welding operations, it may be desirable for welding wire feeders to be portable. Benefits of a portable wire feeder include being able to locate the wire feeder at work area. However, as an operator moves around the work area, a control or display on the wire feeder may become difficult to read and/or reach. In some welding operations, it may be desirable to employ a wire feeder with an adaptable control or display to accommodate the work area.

The present invention defines a wire feeder according to claim <NUM>.

Disclosed are welding systems having one or more adaptable user interfaces, generally. In particular, welding wire feeder systems are equipped with one or more user interfaces adaptable to change position, orientation, or location, relative to a housing or support on which the user interface is secured. The adaptable user interfaces is secured to a mount (e.g., an enclosure, a case, a surface, etc.) via one or more fasteners (e.g., screws, bolts, magnets, straps, snap-fit, detents, pins, etc.). The fasteners create a non-permanent joint between the user interface and the mount, such that the position, orientation, or location user interface can be adapted for a desired application.

Conventional welding systems have control panels and/or user interfaces mounted to the housing in a fixed position. Typically, the panels and/or interfaces are facing forward, such as on a front panel with input/output receptacles, with the expectation that the operator will return to the front panel to perform multiple tasks. However, by the very nature of welding, in particular during use of a portable wire feeder, the operator may move around the work area and may not have a single view of the front panel of the welding system.

Additionally or alternatively, by use of a remote and/or system with an automatic setting feature, the operator may not need to return to the welding power supply and/or wire feeder to perform many common tasks (e.g., adjust welding parameter settings, such as when switching between an arc welding process and a gouging process). Thus, the operator may desire to view the user interface (or access a control on the user interface) from multiple angles.

In an example, a wire feeder may be placed on a cart, along with a spool of wire, tools, etc. If the user interface was in a fixed orientation, the operator must be in a position to clearly see the front panel of the wire feeder. However, if the operator is performing a weld above or below a line of sight of the front panel, the operator would have to leave the work space in order to view and/or access the user interface.

Disclosed adaptable user interfaces are configured to change position, orientation, or location, relative to a housing or support on which the user interface is secured. The user interface may include a display screen and/or controls. Such a display and/or controls may be adaptable to changes in arrangement of the welding system. In some examples, two or more surfaces of the welding system includes such a display and controls. In some examples, the system operational parameters can be displayed and/or controlled from one or more of a plurality of user interfaces arranged on two or more surfaces of the welding system. When the welding system is in a first orientation (arranged vertically), a first display and first set of controls are active, whereas in second orientation (arranged horizontally), a second display and second set of controls are active. Activation of the first or second displays and/or controls can be implemented automatically (e.g., in response to an orientation sensor, a placement sensor, etc.) and/or an operator input (e.g., selection of a particular set of displays/controls). In some examples, the user interface employs a configurable display (which may change orientation of displayed text and/or graphics in response to an adjustment in position, orientation, location, etc.), one or more physical controls (e.g., knobs, switches, membrane switches, etc.), and/or touch screen enabled controls.

In securing the adaptable user interfaces to the housing (e.g., via a mount) a manually adjustable fastener may be employed (e.g., without the use of tools, such as by hand-tightened screws, bolts, magnets, straps, snap-fit, detents, removable pins, etc.). In some examples, a detent is a mechanical or magnetic device configured to resist or arrest the rotation of the user interface about a pivot point. Such a device can include a variety of fasteners, as disclosed herein. Additionally or alternatively, a fastener may employ one or more tools to change the position.

In some examples, the movement or rotation of the user interface is unrestricted, such that the user interface may move <NUM> degrees about the pivot point, may move in one or more degrees of freedom, and/or be removable (e.g., yet maintain a power and/or data connection, by wired and/or wireless connection). For example, a given mount may be able to secure the user interface in a variety of positions, orientations, or locations. In some examples, the housing of the welding system may include multiple mounts configured to receive the user interface, such that the user interface may be removed from a first mount (e.g., with an obstructed view) and secured in a second mount (e.g., with an unobstructed view). In some examples, the user interface comprises a tether or adjustable fastening system (e.g., straps, ties, magnets, etc.), such that an operator may remove the user interface and secure it to any object (e.g., a post, a wall, a lamp, the weld cable, etc.).

In some examples, the mount is fitted with rails to allow the user interface to move within a channel or tract, such that it be conveyed from a first surface (e.g., a lateral side) to a second surface (e.g., a top or bottom side), and/or set at an angle (e.g., by use of a set of pins about which the user interface may pivot). In some examples, the user interface and/or mount may be enclosed within a protective cover (e.g., a cage, a transparent box, etc.) to prevent environmental damage to the user interface while allowing the operator to adjust the position and retain the ability to view and/or access the user interface.

In some examples, the present disclosure may include a wire feeder system with a separate enclosure for a spool of wire. The enclosure for the spool of wire may be separate from and connectable to a portable wire feeder. The portable wire feeder may be significantly lighter than a conventional wire feeder, because the spool of wire is separated from the drive components. Accordingly, both the enclosure for the spool of wire and the wire feeder are easily portable. Additionally, new spools can be conveniently replaced when a welding spool is exhausted.

The wire feeder includes a user interface, a housing comprising a mount to receive the user interface, the user interface being secured to the mount by one or more non-permanent joints to allow the user interface to change an angle or a location of the user interface relative to a surface of the housing on which the user interface is secured, and one or more fasteners configured to allow adjustment of a tension on the user interface from the one or more non-permanent joints.

In some examples, the one or more fasteners comprises one or more of a screw, a bolt, a magnet, a strap, a snap-fit, a detent, a magnet, or a removable pin. In examples, the user interface comprises one or more of a control switch or a display. In some examples, a change in the angle or location of the user interface causes a change in an angle or a location of the control switch or the display of the user interface.

According to the present invention, the user interface is removable from the mount. In some examples, the user interface is configured to be removed from the wire feeder and incorporated with another welding-type system, the user interface configured to control the wire feeder or the welding-type system. In examples, the mount includes rails on which the user interface can move within the mount.

In some examples, the wire feeder is secured in an enclosure. In examples, the enclosure is located on a cart.

<FIG> illustrates a welding system <NUM> for performing welding operations. As shown in the welding system <NUM> of <FIG>, a power supply <NUM> and a wire feeder <NUM> are coupled via conductors or conduits <NUM>. In the illustrated example, the power supply <NUM> is separate from the wire feeder <NUM>, such that the wire feeder <NUM> may be positioned near a welding location at some distance from the power supply <NUM>. Terminals are typically provided on the power supply <NUM> and on the wire feeder <NUM> to allow the conductors <NUM> or conduits to be coupled to the systems so as to allow for power and gas to be provided to the wire feeder <NUM> from the power supply <NUM>, and to allow data to be exchanged between the two devices.

The system <NUM> is configured to provide wire from a welding wire source <NUM>, power from the power supply <NUM>, and shielding gas from a shielding gas supply <NUM>, to a welding tool or torch <NUM>. The torch <NUM> may be any type of arc welding torch, (e.g., GMAW, GTAW, FCAW, SMAW) and may allow for the feed of a welding wire <NUM> (e.g., an electrode wire) and gas to a location adjacent to a workpiece <NUM>. A work cable <NUM> is run to the welding workpiece <NUM> so as to complete an electrical circuit between the power supply <NUM> and the workpiece <NUM>.

The welding system <NUM> is configured for weld settings (e.g., weld parameters, such as voltage, wire feed speed, current, gas flow, inductance, physical weld parameters, advanced welding programs, pulse parameters, etc.) 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 example system <NUM> is configured to allow for welding with various steels, aluminums, or other welding wire that is channeled through the torch <NUM>. Further, the system <NUM> is configured to employ welding wires with a variety of wire sizes. These weld settings are communicated to a control circuit <NUM> within the power supply <NUM>. The system may be particularly adapted to implement welding regimes configured for certain electrode types. The control circuit <NUM> operates to control generation of welding power output that is supplied to the welding wire <NUM> for carrying out the desired welding operation.

The torch <NUM> applies power from the power supply <NUM> to the wire electrode <NUM>, typically by a welding cable <NUM>. Similarly, shielding gas from a shielding gas supply <NUM> is fed through the wire feeder <NUM> and the welding cable <NUM>. During welding operations, the welding wire <NUM> is advanced through a jacket of the welding cable <NUM> towards the torch <NUM>.

The work cable <NUM> and clamp <NUM> allow for closing an electrical circuit from the power supply <NUM> through the welding torch <NUM>, the electrode (wire) <NUM>, and the workpiece <NUM> for maintaining the welding arc during the operation. Although illustrated with a single torch <NUM> connected to the wire feeder <NUM>, in some examples multiple torches of a variety of types may be connected to the wire feeder <NUM>. In examples, a gouging or cutting torch may be separately connected to the wire feeder <NUM> and/or the power supply <NUM>.

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 torch <NUM>. Various power conversion circuits may be employed, including choppers, boost circuitry, buck circuitry, inverters, converters, and/or other switched mode power supply circuitry, and/or any other type of power conversion circuitry. The power conversion circuit <NUM> is coupled to a source of electrical power as indicated by arrow <NUM>. 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 <NUM> 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 wire feeder <NUM> includes a complimentary interface circuit <NUM> that is coupled to the interface circuit <NUM>. In some examples, multi-pin interfaces may be provided on both components and a multi-conductor cable run between the interface circuit to allow for such information as wire feed speeds, processes, selected currents, voltages or power levels, and so forth to be set on either the power supply <NUM>, the wire feeder <NUM>, or both. Additionally or alternatively, the interface circuit <NUM> and the interface circuit <NUM> may communicate wirelessly and/or via the weld cable.

The wire feeder <NUM> also includes control circuit <NUM> coupled to the interface circuit <NUM>. As described below, the control circuit <NUM> allows for wire feed speeds to be controlled in accordance with operator selections or stored sequence instructions, and permits these settings to be fed back to the power supply via the interface circuit. The control circuit <NUM> is coupled to an operator interface <NUM> on the wire feeder that allows selection of one or more welding parameters, particularly wire feed speed. The operator interface may also allow for selection of such weld parameters as the process, the type of wire utilized, current, voltage or power settings, and so forth.

In some examples, the wire feeder <NUM> includes one or more power conversion circuits, which may be similar to power conversion circuit <NUM>. For instance, the power conversion circuits in the wire feeder <NUM> may include choppers, boost circuitry, buck circuitry, inverters, converters, and/or other switched mode power supply circuitry, and/or any other type of power conversion circuitry to control power output to the welding torch <NUM> and/or other type of welding tool, as well as one or more auxiliary outputs.

The control circuit <NUM> may also be coupled to gas control valving <NUM> which regulates and/or measures the flow of shielding gas from the shielding gas supply <NUM> to the torch <NUM>. In general, such gas is provided at the time of welding, and may be turned on immediately preceding the weld and for a short time following the weld. The shielding gas supply <NUM> may be provided in the form of pressurized bottles.

The wire feeder <NUM> includes components for feeding wire to the welding torch <NUM> and thereby to the welding operation, under the control of control circuit <NUM>. As illustrated, the drive components and control components of the wire feeder <NUM> are included within a first housing or enclosure <NUM>. A spool of wire <NUM> is mounted on a spool hub <NUM> in a second housing or enclosure <NUM>. The wire source <NUM> may be integrated with the wire feeder <NUM>. In some examples, the wire source <NUM> is physically independent from the wire feeder <NUM>. In other words, the wire source <NUM> is connectable to and disconnectable from the wire feeder <NUM>, and the wire source <NUM> can be physically moved independently from the wire feeder <NUM>.

In some examples, the spool hub <NUM> is configured to support up to a sixty pound spool of wire and the enclosure <NUM> is large enough to enclose a sixty pound spool of wire. An inlet <NUM> of the wire feeder <NUM> is connected to an outlet <NUM> of the wire source <NUM> via one or more connectors <NUM>. In some examples, the wire feeder inlet <NUM> is directly connected to the wire source outlet <NUM>. For example, the wire feeder inlet <NUM> may include a first connector that directly connects to a second connector of the wire source outlet <NUM>. For example, the wire feeder inlet <NUM> may connect to the wire source outlet <NUM> via quick disconnect connectors or the like through which wire from the spool <NUM> may be fed. In some examples, a conduit may connect the wire feeder inlet <NUM> to the wire source outlet <NUM>. In some examples, the conduit is flexible (e.g., similar to a weld cable). In some examples, the conduit may be a rigid conduit. The connectors <NUM> enable welding wire <NUM> from the spool <NUM> to be fed to the drive components of the wire feeder <NUM>. The connectors <NUM> may also enable one or more control cables to be connected from components within the wire source enclosure <NUM> to the control circuit <NUM>.

Welding wire <NUM> is unspooled from the spool <NUM> and is progressively fed to the torch <NUM>. The spool <NUM> may be associated with a clutch <NUM> that disengages the spool <NUM> when wire is to be fed from the spool <NUM> to the torch <NUM>. The clutch <NUM> may also be regulated, for example by the control circuit <NUM>, to maintain a minimum friction level to avoid free spinning of the spool <NUM>. The first wire feeder motor <NUM> may be provided within a housing <NUM> that engages with wire feed rollers <NUM> to push wire from the wire feeder <NUM> towards the torch <NUM>.

In practice, at least one of the rollers <NUM> is mechanically coupled to the motor <NUM> and is rotated by the motor <NUM> to drive the wire from the wire feeder <NUM>, while the mating roller is biased towards the wire to apply adequate pressure by the two rollers to the wire. Some systems may include multiple rollers of this type. In some examples, the wire feeder <NUM> is configured to feed <NUM>/<NUM> inch wire. In some examples, the wire feeder <NUM> is configured to feed <NUM>/<NUM> inch wire.

A tachometer <NUM> or other sensor may be provided for detecting the speed of the first wire feeder motor <NUM>, the rollers <NUM>, or any other associated component so as to provide an indication of the actual wire feed speed. Signals from the tachometer <NUM> are fed back to the control circuit <NUM> such that the control circuit <NUM> can track the length of wire that has been fed. The length of wire may be used directly to calculate consumption of the wire and/or the length may be converted to wire weight based on the type of wire and its diameter.

In some examples, the user interface <NUM> is adaptable to variations in a position, orientation, or location of a respective welding system (e.g., wire feeder <NUM>). For example, user interface <NUM> may be secured in a mount <NUM>, such as by one or more fasteners <NUM>. The mount <NUM> allows the user interface <NUM> to pivot (on one or more axis), extend from the housing <NUM> (at an angle and/or parallel to the surface from which it extends), and be removed from the mount <NUM> altogether.

A display and/or controls within the user interface <NUM> may be adaptable to changes in arrangement of the welding system. Although illustrated with a single user interface <NUM>, two or more user interfaces may be employed, each adaptable as described herein. Further, although shown on a single surface (and in a single mount), multiple surfaces and/or mounts may be provided on the wire feeder <NUM>. Further, power supply <NUM> may additionally or alternatively employ an adaptable user interface, as disclosed herein.

As disclosed herein, when the wire feeder is in a first location and/or orientation (e.g., arranged vertically and/or at an elevated height), the position, orientation, and/or location of user interface <NUM> may be changed to accommodate the operator's position in the work environment. Similarly, when the wire feeder is in a second location and/or orientation (e.g., arranged horizontally and/or at a reduced height), the position, orientation, and/or location of user interface <NUM> may be changed, as provided herein.

In some examples, the user interface <NUM> employs a configurable display (which may change orientation of displayed text and/or graphics in response to an adjustment in position, orientation, location, etc.), one or more physical controls (e.g., knobs, switches, membrane switches, etc.), and/or touch screen enabled controls. Thus, a change in orientation of the user interface <NUM> from a first position to a second position may make a first control and/or first display window appear to correspond to a second control and/or second display window (due to height, perspective, angle, etc.). Accordingly, the user interface <NUM> may reconfigure the display to correspond to the new perspective (such as automatically, in response to a sensor, and/or from a user input).

In some examples, the user interface <NUM> and/or mount <NUM> may be enclosed within a protective cover (e.g., a cage, a transparent box, etc.) to prevent environmental damage to the user interface <NUM> while allowing the operator to adjust the position and retain the ability to view and/or access the user interface.

<FIG> illustrate perspective views of an example wire feeder <NUM> with an adaptable user interface <NUM>. The wire feeder <NUM> further includes a volt sense terminal <NUM>, a shielding gas outlet <NUM>, and/or a shielding gas inlet <NUM>,. As shown, in <FIG>, the fastener <NUM> can be adjusted (such as by turning) to release tension on the user interface <NUM> within the mount <NUM>. As such, the user interface <NUM> pivots and is angled downward. As shown in <FIG>, the user interface <NUM> pivots and is angled upward.

<FIG> illustrate additional perspective views of an example wire feeder with an adaptable user interface, with <FIG> illustrating the user interface <NUM> pivoting downward, while <FIG> illustrates the user interface <NUM> pivoting upward.

<FIG> illustrate additional views generally of the front perspective of the example wire feeder <NUM>. As shown, <FIG> illustrates the user interface <NUM> pivoting downward, while <FIG> illustrates the user interface <NUM> pivoting upward.

<FIG> illustrate perspective views of the example wire feeder <NUM> with the adaptable user interface <NUM> mounted within an enclosure <NUM>. In the example of <FIG>, the wire feeder <NUM> and/or the enclosure <NUM> may be placed on a cart, along with a spool of wire <NUM>, tools, etc. If the user interface was in a fixed orientation, the operator must be in a position to clearly see the front panel of the wire feeder <NUM>. However, if the operator is performing a weld above or below a line of sight of the front panel, the operator would have to leave the work space in order to view and/or access the user interface.

Claim 1:
A wire feeder (<NUM>) comprising:
a user interface (<NUM>);
a housing (<NUM>) comprising a mount (<NUM>) to receive the user interface (<NUM>),
and the wire feeder (<NUM>) being characterised in that:
the user interface (<NUM>) being secured to the mount (<NUM>) by one or more non-permanent joints to allow the user interface (<NUM>) to change an angle or a location of the user interface (<NUM>) relative to a surface of the housing (<NUM>) on which the user interface (<NUM>) is secured; and
one or more fasteners (<NUM>) configured to allow adjustment of a tension on the user interface (<NUM>) from the one or more non-permanent joints; and
wherein the user interface (<NUM>) is removable from the mount (<NUM>).