Patent Description:
Numerous welding assets may be employed in large welding environments, such as construction sites, factories, manufacturing yards, and shipyards. As welding assets of similar types can be difficult to distinguish from one another, locating a particular welding asset in a large welding environment, or across multiple welding environments, can be difficult and time consuming. Additionally, lost, misplaced, and/or stolen welding assets can be costly to replace. Further, reallocating welding assets from one welding job to another, without first knowing if and/or how the welding assets are being used, can be inefficient. <CIT> (describing all the features and steps of the preamble of claims <NUM> and <NUM>) discloses a welding-type device with a wireless communication unit for transmitting wireless signals. <CIT> discloses the identification of connectivity of a power source and a wire feeder within a weld system. <CIT> discloses a welding quality management system capable of online monitoring of welding parameters in a welding process.

Limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with the present disclosure as set forth in the remainder of the present application with reference to the drawings.

In a first aspect, the present invention defines a welding asset tracking system according to claim <NUM>. In a second aspect, the present invention defines a method according to 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.

Where appropriate, the same or similar reference numerals are used in the figures to refer to similar or identical elements. For example, reference numerals utilizing lettering (e.g., sensor 106a, sensor 106b) refer to instances of the same reference numeral that does not have the lettering (e.g., sensors <NUM>).

<FIG> shows an example of a welding asset tracking system <NUM>. As shown, the welding asset tracking system <NUM> includes an asset tracking server <NUM>, a local positioning system comprising location beacons <NUM>, and an asset tracking network comprising several welding assets <NUM> interconnected via one or more gateways <NUM>, hubs <NUM>, and/or tags <NUM>. As shown, the gateway(s) <NUM>, hub(s) <NUM>, and/or tag(s) <NUM> are retained by the one or more welding assets <NUM>. In some examples, one or more brackets, fasteners, housings, and/or other mechanisms may be used to retain the gateway(s) <NUM>, hub(s) <NUM>, and/or tag(s) <NUM> in and/or on the welding assets <NUM>. In some examples, one or more mobile devices <NUM> (e.g., smartphones, tablet computers, laptop computers, etc.) configured for use with the welding asset tracking system <NUM> may also take on the role of a gateway <NUM>. In some examples, one or more of the gateways <NUM>, hubs <NUM>, and/or tags <NUM> may not be retained by a welding asset <NUM>.

A welding asset <NUM>, as used herein, may refer to any device, equipment, accessory, and/or tool used for welding and/or welding-type activities (e.g., metal fabrication, induction heating, grinding, polishing, plasma cutting, etc.). <FIG> shows several common examples of welding assets <NUM> that may be used with the welding asset tracking system <NUM>. As shown, common welding assets <NUM> may include a welding (and/or welding-type) power supply <NUM>, a power supply pendant <NUM>, a gas bottle regulator <NUM>, a gas bottle <NUM>, a welding wire feeder <NUM>, a wire spool <NUM>, a wire barrel <NUM>, a welding torch <NUM>, a foot pedal <NUM>, a respirator mask <NUM>, a welding helmet <NUM>, a light <NUM> (e.g., attached to, or separate from, the welding helmet <NUM>), a powered air-purifying respirator (PAPR) <NUM>, a supplied air respirator (SAR) <NUM>, a fume extractor <NUM> (e.g., to extract welding fumes), a box filtration system <NUM>, a grinder <NUM>, an operator id badge <NUM>, welding material <NUM> (e.g., welding workpiece(s)), and a welding work order <NUM> (e.g., affixed to a bin or pallet containing welding material <NUM>, or the welding material <NUM> itself). In some examples, the welding torch <NUM> may be a welding gun or plasma torch. In some examples, the welding torch <NUM> may be robot and/or machine operated.

In the example of <FIG>, each welding asset <NUM> includes one or more sensors <NUM>. In some examples, the one or more sensors <NUM> may be configured to continuously and/or periodically sense, detect, measure, and/or record sensor data relating to the operation(s) (and/or error(s)) of that particular welding asset <NUM>. For example, a welding power supply <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record an input, intermediate, and/or output current and/or voltage, an arc time, a cooling airflow amount, a cooling device (e.g., fan) on time, a weld start/stop time, and/or a total energy amount outputted. As another example, a wire feeder <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record a wire feed speed, a motor current, motor voltage, a cooling airflow amount, a cooling device (e.g., fan) on time, roller torque, roller speed, and/or a total amount of filler material output. As another example, a gas regulator <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record gas flow rate, gas temperature, gas mixture, and/or total gas output. As another example, a welding helmet <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record temperature in and/or around the welding helmet <NUM>, air quality in and/or around the welding helmet <NUM>, motion of the welding helmet <NUM>, whether the helmet <NUM> is in a darkened state (e.g., for auto-darkening helmets), and/or the total amount of time spent in the darkened state (and/or undarkened state). As another example, a welding torch <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record trigger activation start/stop time, activation duration, arc time, position (e.g., with respect to welding material <NUM> and/or a fixture), orientation (e.g., with respect to welding material <NUM> and/or a fixture), motion (e.g., with respect to welding material <NUM> and/or a fixture), current, and/or voltage. As another example, a foot pedal <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record pedal activation start/stop time, activation duration, and/or activation pressure. As another example, a pendant <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record a recent command history. As another example, an operator badge <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record a scanning history (e.g., where the badge is scanned when entering/exiting certain areas and/or using certain assets). As another example, a PAPR <NUM> or fume extractor <NUM> may have one or more sensors <NUM> configured to sense, detect, measure, and/or record air circulation amounts, air quality, air temperature, and/or a condition of a filter.

In some examples, the one or more sensors <NUM> may detect and/or record a time corresponding to the sensing, detection, measurement, and/or recording of the sensor data. In some examples, one or more of the welding assets <NUM> may have no sensor <NUM>. In some examples, a stand-alone sensor <NUM> configured to be removably attached to some third party (e.g., competitor) welding asset may be considered a welding asset <NUM> in and of itself. For example, a Hall Effect sensor or magnetic reed switch sensor configured to be attached to a welding cable and/or detect current through the welding cable may be fitted with its own tag <NUM>, effectively making the sensor <NUM> itself a welding asset <NUM>. As another example, an air flow sensor configured to be attached to a welding power supply <NUM> (e.g., within the interior and/or in fluid communication with external vents) may be configured to detect cooling air circulating through the welding power supply <NUM> and fitted with its own tag <NUM>, effectively making the sensor <NUM> itself a welding asset <NUM>.

In the example of <FIG>, each sensor <NUM> has an electrical and/or communication link to a tag <NUM>, hub <NUM>, and/or gateway <NUM> retained by a welding asset <NUM>. Through this link, sensor data sensed, detected, measured, and/or recorded by the sensor may be communicated to the tag <NUM>, hub <NUM>, and/or gateway <NUM> retained by the welding asset <NUM>. As shown, the tag <NUM>, hub <NUM>, and gateway <NUM> have tag memory circuitry <NUM>, hub memory circuitry <NUM>, and gateway memory circuitry <NUM>, respectively, configured to store the sensor data. In some examples, the tag memory circuitry <NUM>, hub memory circuitry <NUM>, and/or gateway memory circuitry <NUM> may also store a time corresponding to the detection, measurement, recordation, and/or reception of the sensor data. In some examples, the tag memory circuitry <NUM>, hub memory circuitry <NUM>, and/or gateway memory circuitry <NUM> may also store some other data related to the welding asset <NUM>. The tag memory circuitry <NUM>, hub memory circuitry <NUM>, and/or gateway memory circuitry <NUM> may also store an identifier (e.g., serial number) that is unique within the welding asset tracking system <NUM> and/or associated with the welding asset <NUM> retaining the tag <NUM>, hub <NUM>, or gateway <NUM> (and/or associated with the tag <NUM>, hub <NUM>, or gateway <NUM> itself).

In some examples, smaller and/or less sophisticated welding assets 200c (e.g., wire spools <NUM>, work orders <NUM>, welding material <NUM>, operator badges <NUM>, welding guns <NUM>, grinders <NUM>, welding helmets <NUM>, etc.), and/or welding assets 200c that change location frequently, may retain tags <NUM>. In some examples, the tags <NUM> may be relatively cheap and/or simple devices and/or mechanisms. In the example of <FIG>, the tag <NUM> includes tag communication circuitry <NUM> and tag memory circuitry <NUM> in electrical communication with one another. As discussed above, the tag memory circuitry <NUM> may store sensor data, one or more identifiers, and/or other data related to the retaining welding asset 200c. The tag communication circuitry <NUM> may be configured for shorter range communication, such as, for example, via a short wavelength ultra-high frequency protocol (commonly referred to as Bluetooth), an IEEE <NUM>. <NUM> standard protocol (commonly referred to as Zigbee), a near field communication (NFC) protocol, and/or a radio frequency identification (RFID) protocol. In some examples, the tag communication circuitry <NUM> may communicate data (i.e., tag data) stored in the tag memory circuitry <NUM> via the tag communication circuitry <NUM>.

In some examples, a tag <NUM> may be so simple as to have no circuitry. For example, a simple welding asset <NUM> (e.g., wire spool) with no sensor <NUM> may record no dynamic data and/or have no need of dynamically updatable memory circuitry. In such an example, a tag <NUM> may be implemented via a (e.g., linear and/or one dimensional) barcode <NUM> or matrix (and/or two dimensional) barcode <NUM>. In some examples, the tag <NUM> (and/or barcode <NUM> or matrix barcode <NUM>) may be retained on an outside of the welding asset 200a or within a housing, chassis, cover, etc. of the welding asset 200a.

In some examples, moderately sized and/or moderately sophisticated welding assets 200b (e.g., welding helmets <NUM>, wire feeders <NUM>, power supplies <NUM>), and/or welding assets <NUM> that only change locations occasionally, may retain hubs <NUM>. In some examples, the hubs <NUM> may be retained on an outside of welding assets 200b or within a housing, chassis, cover, etc. of the welding assets 200b. In some examples, the hub retaining welding assets 200b may have existing circuitry (e.g., memory, control, and/or communication circuitry) that can be supplemented relatively easily and/or cheaply to give the welding assets 200b capabilities of a hub <NUM>.

In the example of <FIG>, the hub <NUM> includes hub memory circuitry <NUM>, hub control circuitry <NUM>, and hub communication circuitry <NUM>, in electrical communication with one another. In addition to identifiers and/or sensor data, the hub memory circuitry <NUM> is shown storing a hub tracking program <NUM> that guides the hub <NUM> in fulfilling its role in the welding asset tracking system <NUM>, as discussed further below. The hub control circuitry <NUM> controls the operation of the hub <NUM> in accordance with the hub tracking program <NUM>. In some examples, the hub control circuitry <NUM> may comprise one or more processors.

In the example of <FIG>, the hub communication circuitry <NUM> includes short range hub communication circuitry <NUM>. In some examples, the short range hub communication circuitry <NUM> may be configured for shorter range wireless communication, such as, for example, via a short wavelength ultra-high frequency protocol (commonly referred to as Bluetooth), an IEEE <NUM>. <NUM> standard protocol (commonly referred to as Zigbee), an NFC protocol, and/or an RFID protocol. In some examples, the hub <NUM> may obtain tag data from nearby tags <NUM> (and/or their tag communication circuitry <NUM> and/or tag memory circuitry <NUM>) in communication range using the short range hub communication circuitry <NUM>. In some examples, a hub <NUM> may be configured to only communicate with and/or obtain tag data from specific tags <NUM>, specific welding assets <NUM>, and/or specific types of welding assets <NUM> (e.g., based on identifier(s)).

In the example of <FIG>, the hub <NUM> is linked to a barcode scanner <NUM> configured to obtain tag data from a barcode <NUM> and/or matrix barcode <NUM>. In some examples, the hub <NUM> may use the barcode scanner <NUM> instead of, or in addition to, the short range hub communication circuitry <NUM> to obtain tag data. For example, a wire feeder <NUM> (comprising a welding asset 200b) may have a barcode scanner <NUM> positioned and/or configured to scan a barcode <NUM> or matrix barcode <NUM> imprinted on an outer portion of a wire spool <NUM> when the wire spool <NUM> is loaded into the wire feeder <NUM>. In some examples, the hub <NUM> may store the tag data (as well as a corresponding time the tag data is sent and/or received) in hub memory circuitry <NUM>.

In the example of <FIG>, the hub communication circuitry <NUM> also includes long range hub communication circuitry <NUM>. In some examples, the long range hub communication circuitry <NUM> may be configured for longer range wireless communications, such as, for example, via a cellular and/or IEEE <NUM> standard (commonly referred to as WiFi) protocol. As shown, the hub <NUM> may be in communication with one or more gateways <NUM> of the welding asset tracking system <NUM> via the long range hub communication circuitry <NUM>. In some examples, the hub <NUM> may send tag data obtained from nearby tags <NUM> to one or more gateways <NUM> in communication with the hub <NUM> via the long range hub communication circuitry <NUM>. In some examples, the hub <NUM> may additionally, or alternatively, send an identifier of the welding asset 200b (and/or hub <NUM>), sensor data from the sensor 106b, and/or other data relating to the welding asset 200b to one or more gateways <NUM> in communication with the hub <NUM> via the long range hub communication circuitry <NUM>. Collectively, this data may be referred to as hub data. In some examples, the hub <NUM> may send tag data and/or hub data directly to the asset tracking server <NUM> via the long range hub communication circuitry <NUM>. In some examples, the hub <NUM> may send the tag data and/or hub data to a second hub <NUM> of the welding asset tracking system <NUM>, such as, for example, if the hub communication circuitry <NUM> is unable to establish communication with a gateway <NUM> and/or the asset tracking server <NUM>. In such an example, the second hub <NUM> may either be in communication with a gateway <NUM> (in which case tag data and/or hub data may be sent to the gateway <NUM>) or also unable to establish communication with a gateway <NUM>. If the second hub <NUM> is also unable to establish communication with a gateway <NUM>, the tag data and/or hub data may be forwarded to a third hub <NUM> (and so on and so on until the data arrives at a hub <NUM> in communication with a gateway <NUM>).

In the example of <FIG>, the gateway <NUM> is retained by a welding asset 200a. In some examples, larger and/or more sophisticated welding assets 200a (e.g., wire feeders <NUM>, power supplies <NUM>, etc.), and/or welding assets 200a that rarely change location significantly, may retain gateways <NUM>. In some examples, the gateways <NUM> may be more sophisticated and/or expensive devices. Nevertheless, in some examples, the welding assets 200a may have existing circuitry that can be supplemented relatively easily and/or cheaply to give the welding asset 200a gateway capabilities.

In the example of <FIG>, each gateway <NUM> includes gateway memory circuitry <NUM>, gateway control circuitry <NUM>, and gateway communication circuitry <NUM> in electrical communication with one another. In addition to identifiers and/or sensor data, the gateway memory circuitry <NUM> stores a gateway tracking program <NUM> that guides the gateway <NUM> in fulfilling its role in the welding asset tracking system <NUM>, as discussed further below. The gateway control circuitry <NUM> controls the operation of the gateway <NUM> in accordance with the gateway tracking program <NUM>. In some examples, the gateway control circuitry <NUM> may comprise one or more processors.

In the example of <FIG>, the gateway communication circuitry <NUM> includes short range gateway communication circuitry <NUM>. In some examples, the short range gateway communication circuitry <NUM> may be configured for shorter range wireless communication, such as, for example, via a short wavelength ultra-high frequency protocol (commonly referred to as Bluetooth), an IEEE <NUM>. <NUM> standard protocol (commonly referred to as Zigbee), an NFC protocol, and/or an RFID protocol. In some examples, the gateway <NUM> may obtain tag data from nearby tags <NUM> and/or hub data from nearby hubs <NUM> (in communication range using the short range gateway communication circuitry <NUM>. Though not shown, in some examples, the gateway <NUM> may be linked to a barcode scanner <NUM> and obtain tag data from a barcode <NUM> and/or matrix barcode <NUM> using the barcode scanner <NUM>. In some examples, the gateway <NUM> may store the tag data and/or hub data (as well as a corresponding time the tag/hub data is sent and/or received) in gateway memory circuitry <NUM>.

In the example of <FIG>, the gateway communication circuitry <NUM> also includes long range gateway communication circuitry <NUM>. In some examples, the long range gateway communication circuitry <NUM> may be configured for longer range wireless communications, such as, for example, via a cellular and/or IEEE <NUM> standard (commonly referred to as WiFi) protocol. As shown, the gateway <NUM> may be in communication with one or more hubs <NUM> of the welding asset tracking system <NUM> via the long range gateway communication circuitry <NUM>. In some examples, the gateway <NUM> may receive hub data (and/or asset identifiers, sensor data, timestamps, etc.) obtained from nearby hubs <NUM> via the long range gateway communication circuitry <NUM>. In some examples, the gateway <NUM> may also communicate with other gateways <NUM> of the welding asset tracking system <NUM> via the gateway communication circuitry <NUM> (long and/or short range).

In the example of <FIG>, the gateway <NUM> also includes global positioning system (GPS) communication circuitry <NUM>. As shown, the gateway <NUM> is in communication with an external positioning system <NUM> (e.g., GPS, Wifi, and/or cellular positioning system). In some examples, the GPS communication circuitry <NUM> may enable communication with the external positioning system <NUM>. In some examples, the external positioning system <NUM> may provide the gateway <NUM> with a position (e.g., latitude and/or longitude) of the gateway <NUM> and/or retaining welding asset 200a via the external positioning system <NUM> and/or GPS communication circuitry <NUM>. In some examples, one or more hubs <NUM> may also have GPS communication circuitry <NUM> (and/or other appropriate communication circuitry) with which to communicate with, and/or obtain position information from, the external positioning system <NUM>.

In the example of <FIG>, the hubs <NUM> are in communication (e.g., via short range hub communication circuitry <NUM>) with a local positioning system comprising location beacons <NUM>. In some examples, the gateways <NUM> may also be in communication (e.g., via short range gateway communication circuitry <NUM>) with the local positioning system. The local positioning system is used to estimate and/or determine a (relative, local, and/or global) position of a gateway <NUM>, hub <NUM>, tag <NUM>, and/or welding asset <NUM>, such as, for example, in situations where the external positioning system <NUM> is unavailable, unreachable, and/or otherwise not an option. Multiple location beacons <NUM> are positioned throughout a welding area to provide a dense, granular, and/or more precise local positioning system.

In the example of <FIG>, the location beacon <NUM> of the local positioning system includes beacon memory circuitry <NUM>, beacon communication circuitry <NUM>, and a beacon user interface (UI) <NUM> in electrical communication with one another. As shown, the beacon memory circuitry <NUM> stores a location <NUM> of the beacon <NUM>. This beacon location <NUM> may be a relative position (e.g., <NUM> feet NW of beacon <NUM>, halfway between front door and western window, etc.), a local position (e.g., welding cell <NUM>, back door, front wall, loading bay, etc.), and/or a global position (e.g., <NUM>° N, <NUM>° W). In some examples, the beacon location <NUM> may be entered and/or modified via the beacon UI <NUM>. In some examples, the beacon location <NUM> may be entered and/or modified via a third party device (e.g., mobile device <NUM>) in communication with the location beacon <NUM> (e.g., via beacon communication circuitry <NUM>). In some examples, the beacon location <NUM> may be communicated to hubs <NUM> and/or gateways <NUM> in communication range via beacon communication circuitry <NUM>.

In some examples, a maximum communication range of the beacon communication circuitry <NUM> may be reduced to a set communication range. This reduction may be achieved via beacon UI <NUM> and/or third party device in communication with the beacon communication circuitry <NUM>, for example. In some examples, the maximum communication range and/or set communication range may be stored in the beacon memory circuitry <NUM>, and/or accessed when determining position.

In some examples, the hubs <NUM> and/or gateways <NUM> of the welding asset tracking system <NUM> may determine their positions via the external positioning system <NUM> and/or local positioning system. For example, a gateway <NUM> in communication with the external positioning system <NUM> may determine its global position via GPS communication circuitry <NUM>, and send this position to the asset tracking server(s) <NUM>. Thereafter, the asset tracking server <NUM> (and/or the gateway <NUM> itself) may determine and/or estimate a position of any gateways <NUM>, hubs <NUM>, and/or tags <NUM> for which the gateway <NUM> has obtained (and/or communicated) data. As another example, a hub <NUM> that cannot access the external positioning system <NUM> may nonetheless access one or more location beacons <NUM> of the local positioning system and thereby estimate and/or determine its position based on the beacon locations <NUM> of the location beacons <NUM>. Thereafter, the asset tracking server <NUM> (and/or hub <NUM> itself or some gateway <NUM>) may determine and/or estimate a position of any hubs <NUM> and/or tags <NUM> for which the hub <NUM> has obtained (and/or communicated) data.

In some examples, the determination and/or estimation of position may include a position radius and/or a zone of uncertainty (e.g., position within <NUM> meters of gateway <NUM>, or somewhere within facility <NUM>). In some examples, the position determination and/or estimation may be made more accurate and/or precise by using multiple location beacons <NUM> in combination with trilateration and/or triangulation methods. In some examples, the position determination and/or estimation may be made more accurate and/or precise by using other factors (e.g., the communication range, signal strength, signal time of flight, signal direction, etc.). In some examples, the gateway(s) <NUM> and/or hub(s) <NUM> may be configured with a plurality of antennas (e.g., <NUM>, <NUM>, <NUM>, etc.) to facilitate detection of signal direction (e.g., by determining which antenna(s) first receive the signal). In some examples, the position information of the external positioning system <NUM> and local positioning system may be combine to more accurately and/or precisely determine position.

In some examples, one or more gateways <NUM>, hubs <NUM>, tags <NUM>, and/or sensors <NUM> may have their position stored in their own respective memory circuitry, so that position may be determined without resorting to an external positioning system. In some examples, the gateways <NUM>, hubs <NUM>, tags <NUM>, and/or sensors <NUM> may also be setup, updated, paired, and/or otherwise configured with position information (and/or other information) via a third party device (e.g., mobile device <NUM>) in communication with the gateway <NUM>, hub <NUM>, tag <NUM>, and/or sensor <NUM>. In some examples, the gateways <NUM>, hubs <NUM>, tags <NUM>, and/or sensors <NUM> retained by welding assets <NUM> may be setup, paired, and/or otherwise configured via an interface of the retaining welding asset <NUM>.

In the example of <FIG>, the gateway <NUM> is also in communication with one or more asset tracking server(s) <NUM> through a network <NUM> (e.g., local area network, wide area network, internet, etc.). In some examples, the gateway <NUM> may be in communication with the asset tracking server(s) <NUM> directly, without going through the network <NUM>. In some examples, the gateway communication circuitry <NUM> (e.g., the long range gateway communication circuitry <NUM>) may be configured to facilitate communication with the asset tracking server(s) <NUM> and/or network <NUM>. In some examples, the asset tracking server(s) <NUM> may be implemented in one or more gateways <NUM>.

In some examples, the gateways <NUM> may send information obtained from other gateways <NUM>, hubs <NUM>, and/or tags <NUM> to the asset tracking server(s) <NUM>. In some examples, one or more hubs <NUM> may also be in communication with the asset tracking server(s) <NUM>, and/or send information obtained from other hubs <NUM>, and/or tags <NUM> to the asset tracking server(s) <NUM> without going through the gateway(s) <NUM>. In some examples, one or more mobile devices <NUM> configured for use with the welding asset tracking system <NUM> may also take on the role of gateways <NUM> and send information obtained from other gateways <NUM>, hubs <NUM>, and/or tags <NUM> to the asset tracking server(s) <NUM>. For example, one or more welding operators, administrators, maintenance workers, technicians, etc. may carry mobile devices <NUM> configured to act as mobile gateways <NUM> with the welding asset tracking system <NUM>. In such an example, the mobile gateways <NUM> may obtain location, hub, and/or tag data (and/or gateway data) when in proximity to location beacons <NUM>, gateways <NUM>, hubs <NUM>, and/or tags, and send the data to the asset tracking server(s) <NUM>.

In the example of <FIG>, the one or more asset tracking servers <NUM> include server communication circuitry <NUM>, server processing circuitry <NUM>, and server memory circuitry <NUM> in electrical communication with one another. In some examples, only one asset tracking server <NUM> may be used. In some examples, multiple asset tracking servers <NUM> may be used. As shown, the one or more asset tracking servers <NUM> are in communication with one or more gateways <NUM> through the network <NUM>. In some examples, the asset tracking server(s) <NUM> may be in communication with one or more hubs <NUM> as well. In some examples, the asset tracking server(s) <NUM> may be in communication with the one or more gateways <NUM> and/or hubs <NUM> directly, without going through the network <NUM>. In some examples, the server communication circuitry <NUM> may facilitate communication with the network <NUM>, gateways <NUM>, and/or hubs <NUM>.

In the example of <FIG>, the server memory circuitry <NUM> stores an asset tracking database <NUM> and an asset tracking program <NUM>. In some examples, the asset tracking database <NUM> may store data obtained from the gateways <NUM>, hubs <NUM>, tags <NUM>, and/or sensors <NUM> of the welding asset tracking system <NUM>. In some examples, certain data may be associated in the asset tracking database <NUM> to facilitate reporting, analysis, and/or tracking. For example, sensor data obtained from multiple sensors <NUM> of the same welding asset <NUM> may be linked and/or associated. As another example, data pertaining to the same welding assets, or welding assets of the same or similar type, at the same or similar location, used by the same or similar operators, and/or involved the same or similar operations, may be linked and/or associated. In some examples, the asset tracking database <NUM> may be stored in the server memory circuitry <NUM> of one asset tracking server <NUM>. In some examples, duplicates of the asset tracking database <NUM> may be stored across several asset tracking servers <NUM>. In some examples, different portions of the asset tracking database <NUM> may be stored in several different asset tracking servers <NUM>.

In the example of <FIG>, the server memory circuitry <NUM> further stores an asset tracking program <NUM>. In some examples, the asset tracking program <NUM> may comprise computer (and/or processor) readable (and/or executable) instructions. In some examples, the server processing circuitry <NUM> may control the operation of the asset tracking server <NUM> in accordance with the asset tracking program <NUM>. In some examples, the server processing circuitry <NUM> may comprise one or more processors.

In some examples, the asset tracking program <NUM> may direct the server processing circuitry <NUM> to organize and/or store data received via the asset tracking network in the asset tracking database <NUM>. In some examples, the asset tracking program <NUM> may further direct the asset tracking server(s) <NUM> to parse the data in the asset tracking database <NUM>, such as in response to one or more user requests (e.g., received from a terminal and/or other device in communication with the asset tracking server(s) <NUM>). For example, the asset tracking server <NUM> may receive one or more requests to locate a particular welding asset, a particular welding asset type, welding assets in a particular location, welding assets performing a particular operation, welding assets used by a particular operator, etc. In response, the asset tracking server <NUM> may query and/or parse the data in asset tracking database <NUM> to respond to the request.

<FIG> is a diagram illustrating components of the welding asset tracking system <NUM> distributed within an example welding area <NUM>. As shown, several gateway retaining welding assets 200a, hub retaining welding assets 200b, and tag retaining welding assets 200c are positioned throughout the welding area <NUM>. A plurality of location beacons <NUM> are also arranged in a grid configuration within the welding area <NUM>. The grid configuration increases the likelihood that there will be at least one location beacon <NUM> nearby that can be used to determine position. Two welding operators <NUM> with mobile devices <NUM> that may operate as gateways <NUM> are also shown in the welding area <NUM>.

In the example of <FIG>, there are more tag retaining welding assets 200c than hub retaining welding assets 200b, and more hub retaining welding assets 200b than gateway retaining welding assets 200a. This may reflect a real world situation, and may help illustrate the economics of the welding asset tracking system <NUM>. Using low cost tags <NUM> with the numerous tag retaining welding assets 200c may help to keep costs manageable. The fewer hub retaining welding assets 200b and gateway retaining welding assets 200a means that fewer pricey hubs <NUM> are used, and still fewer even pricier gateways <NUM>.

Despite being fewer in number than the tag retaining welding assets 200c (and/or tags <NUM>), the hub retaining welding assets 200b and gateway retaining welding assets 200a (and/or associated hubs <NUM> and gateways <NUM>) nevertheless form a relatively dense asset tracking network. The majority of tag retaining welding assets 200c (and/or tags <NUM>) are within close proximity to at least one hub retaining welding asset 200b or gateway retaining welding asset 200a. As shown, all the hub retaining welding assets 200b are in proximity to at least one hub retaining welding asset 200b or gateway retaining welding asset 200a. In examples where no gateway <NUM> is in proximity, a hub <NUM> may send its data to another hub <NUM> in proximity, and so on and so forth, until the data arrives at a gateway <NUM> (or a mobile device <NUM> or hub <NUM> with gateway capabilities). The density of the hubs <NUM> and gateways <NUM>, as well as the mesh like network forwarding capabilities of the hubs <NUM>, may help ensure that data can be relatively consistently collected and/or uploaded to the asset tracking server <NUM>. Further, this density may be representative of real world situations, where often times multiple welding assets <NUM> are used in relatively close proximity to one another, and rarely is a welding asset <NUM> left isolated far from other welding assets <NUM>. While the mobile devices <NUM> operating as gateways <NUM> may be valuable supplements, such as in those cases where one or more welding assets <NUM> are isolated, they are not a necessity. Thus, the system can still operate well even if operators <NUM> with mobile devices <NUM> are only rarely (or never) in the welding area <NUM>.

<FIG> is a flowchart illustrating an example hub tracking program <NUM> of the welding asset tracking system <NUM> of <FIG>. In some examples, the hub tracking program <NUM> may be implemented in computer (and/or processor) readable (and/or executable) instructions. While shown as being stored in hub memory circuitry <NUM>, in some examples, the hub tracking program <NUM> may be implemented in discrete analog and/or digital circuitry. While <FIG> is described in terms of the hub tracking program <NUM>, in some examples, the gateway tracking program <NUM> may operate very similarly to the hub tracking program <NUM> (e.g., with respect to a gateway <NUM> and/or gateway retaining welding asset 120a instead of hub <NUM> and/or hub retaining welding asset 120b). In some examples, portions of the hub tracking program <NUM> may also be performed by the asset tracking program <NUM>.

In the example of <FIG>, the hub tracking program <NUM> begins at block <NUM>. At block <NUM>, the hub tracking program <NUM> obtains data from one or more tags <NUM> and/or hubs <NUM> in communication range. In some examples, this may comprise reading one or more barcodes <NUM> and/or matrix barcodes <NUM> via a barcode scanner <NUM>, communicating with tag communication circuitry <NUM> via the hub communication circuitry <NUM>, and/or communications between hub communication circuitry <NUM>. In some examples, the tag data obtained from the tags <NUM> may include sensor data read from one or more sensors 106c of the tag retaining welding asset(s) 200c, one or more identifiers, location data of the welding asset(s) 200c, and/or other data pertaining to the tag(s) <NUM> and/or welding asset(s) 200c. In some examples, hub data obtained from other hubs <NUM> may include sensor data read from one or more sensors 106b of the hub retaining welding asset(s) 200b, one or more identifiers, location data of the hub retaining welding asset(s) 200b, tag data obtained by the one or more hubs <NUM>, and/or other data pertaining to the hub(s) <NUM> and/or welding asset(s) 200b. In some examples, the hub tracking program <NUM> may only obtain data from, and/or transmit data to, certain (e.g., authorized, paired, grouped, etc.) gateways <NUM>, hubs <NUM>, and/or tags <NUM>.

In the example of <FIG>, the hub tracking program proceeds to block <NUM> after block <NUM>. At block <NUM>, the hub tracking program <NUM> determines whether the data received at block <NUM> includes location data for the various tags <NUM>, hubs <NUM>, and/or welding assets <NUM>. In some examples, this determination may comprise parsing the tag data and/or hub data received at block <NUM>. In some examples, this determination may instead be performed at the asset tracking server <NUM> by the asset tracking program <NUM>.

In the example of <FIG>, the hub tracking program proceeds to block <NUM> if there is some missing location data. At block <NUM>, the hub tracking program <NUM> determines the location of the one or more tag retaining welding assets 200c, tags <NUM>, hub retaining welding assets 200b, and/or hubs <NUM> from which data was received at block <NUM>. Block <NUM> is described in more detail below with respect to <FIG>. As shown, the hub tracking program <NUM> proceeds to block <NUM> if the data received at block <NUM> is not missing location data, and/or after completion of block <NUM>.

In the example of <FIG>, the hub tracking program <NUM> obtains sensor data from the sensor 106b of the hub retaining asset 200b at block <NUM>. After block <NUM>, the hub tracking program <NUM> proceeds to block <NUM>. At block <NUM>, the hub tracking program <NUM> determines whether the location of the hub retaining asset 200b (and/or hub <NUM>) is known. In some examples, this determination may comprise checking the hub memory circuitry <NUM> to see if a location is stored, checking the hub memory circuitry <NUM> to see if the asset tracking server <NUM> knows (and/or stores) the location of the hub retaining asset 200b (and/or hub <NUM>), and/or checking whether block 450a was executed, as execution of block 450a may involve determining the location of the hub retaining asset 200b (and/or hub <NUM>).

In the example of <FIG>, the hub tracking program <NUM> proceeds to block 450b if the location of the hub retaining welding asset 200b is not known. Block 450b is described in detail below with respect to <FIG>. In some examples, the determination at blocks <NUM> and 450b may only occur periodically (e.g., once per predetermined, programmatically determined, or otherwise set time period), rather than every time data is sent to the asset tracking server(s) <NUM> (and/or gateway(s) <NUM>). In the example of <FIG>, if the location of the hub retaining welding asset 200b (and/or hub <NUM>) is known, the hub tracking program <NUM> proceeds to block <NUM> where the hub tracking program <NUM> sends the sensor data and any other data (e.g., tag data, hub data, location data, identifiers) to the asset tracking server <NUM>. In some examples, the data may be sent to the asset tracking server <NUM> through one or more intervening hubs <NUM> and/or gateways <NUM>. After block <NUM>, the hub tracking program <NUM> ends.

<FIG> is a flowchart illustrating the determine asset location(s) blocks 450a and 450b of the hub tracking program <NUM> of <FIG> in more detail. As shown, the determine asset location(s) block <NUM> begins at block <NUM>, where the hub tracking program <NUM> determines whether the hub communication circuitry <NUM> is configured to access an external positioning system <NUM> (e.g., GPS, Wifi, and/or cellular positioning system). If so, the hub tracking program <NUM> proceeds to block <NUM> where the position of the hub retaining welding asset 200b (and/or hub <NUM>) is determined via communication with the external positioning system <NUM>. In some examples, the determined position may comprise an approximate position with a radius of uncertainty (e.g., position is within <NUM> radius of given latitude/longitude). In some examples, the hub tracking program <NUM> may also use the local positioning system at block <NUM> (e.g., to more precisely determine the location).

If the hub tracking program <NUM> determines the hub communication circuitry is not configured to access an external positioning system <NUM>, the hub tracking program <NUM> proceeds to block <NUM>. At block <NUM>, the hub tracking program <NUM> uses the local positioning system to determine a location of the hub retaining welding asset 200b (and/or hub <NUM>). In some examples, this may comprise communicating (e.g., via hub communication circuitry <NUM>) with the location beacons <NUM> in communication range of the hub <NUM> to obtain the beacon locations <NUM> corresponding to the location beacons <NUM> In some examples, the hub tracking program <NUM> may determine a location of the hub retaining welding asset 200b using the location beacons <NUM>. In some examples, the determined location may comprise an approximate location with a degree of uncertainty (e.g., position is within <NUM> radius of given latitude/longitude, position is somewhere within welding cell <NUM>, etc.). In some examples, the degree of uncertainty may be based at least partially on the communication range of the beacon communication circuitry <NUM> and/or hub communication circuitry <NUM> (e.g., hub <NUM> within communication range of beacon location <NUM>). In examples, where more than one location beacons <NUM> and/or beacon locations <NUM> are used, the hub tracking program <NUM> may use trilateration and/or triangulation methods to make the location more precise.

In the example of <FIG>, the hub tracking program <NUM> proceeds to block <NUM> after block <NUM> and/or block <NUM>. At block <NUM>, the hub tracking program <NUM> determines one or more other locations of one or more other welding assets <NUM>. In some examples, the hub tracking program <NUM> may determine the other locations of the one or more other welding assets <NUM> based on the determined location of the hub retaining welding asset <NUM>. For example, the hub tracking program <NUM> may consider the communication range of the tag communication circuitry <NUM> with which the hub communication circuitry <NUM> has communicated (and/or the hub communication circuitry <NUM>), and determine that the corresponding tag <NUM> and/or tag retaining welding asset 200c must be within communication range of the location of the hub <NUM>. As another example, the hub tracking program <NUM> may determine that the tag data was obtained via the barcode scanner <NUM>, and determine that the corresponding tag <NUM> and/or tag retaining welding asset 200c must be within a scanning of the barcode scanner <NUM>. In some examples, the hub tracking program <NUM> may send the determined location(s) (and/or time(s) of the determination(s)) to the welding asset(s) <NUM> (and/or retained tag(s) <NUM>, hub(s) <NUM>, and/or gateway(s) <NUM>) for storage in memory circuitry, and/or store the location(s) in the hub memory circuitry <NUM>.

In some examples, block <NUM> may be performed by the asset tracking program <NUM> rather than the hub tracking program <NUM>. For example, hubs <NUM> and/or gateways <NUM> may periodically determine their own locations and send to the asset tracking server <NUM> (along with their identifier(s)). Thereafter, the asset tracking program <NUM> may determine which hub <NUM> and/or gateway <NUM> obtained which tag data (and/or hub data) and use the last received location of the hub and/or gateway <NUM> to determine the location of the tag retaining welding asset 200c corresponding to the tag data (and/or hub retaining welding asset 200b corresponding to the hub data). In some examples, (e.g., at block 450b of <FIG>), block <NUM> may be skipped altogether. In the example of <FIG>, the determine asset location(s) block <NUM> of the hub tracking program <NUM> ends after block <NUM>.

By having welding assets <NUM> retain the gateways <NUM>, hubs <NUM>, and/or tags <NUM>, the disclosed welding asset tracking system <NUM> becomes more likely to have the density necessary for more granular tracking due to the tendency of welding assets <NUM> being positioned near other welding assets <NUM>. Additionally, using devices with varying sophistication levels and/or costs allows the welding asset tracking system <NUM> to be implemented economically, and according to the sophistication levels, costs, and/or portability of the various welding assets <NUM>. Further, the inclusion of a local positioning system allows the welding asset tracking system <NUM> to operate even where an external positioning system <NUM> is unavailable (which may sometimes be the case in certain welding areas). In this way, the welding asset tracking server may continually receive updated information regarding each welding assets identity, location, and/or use. This updated information may be used by a welding asset manager to locate welding assets, allocate assets to different welding jobs, as well as determine whether assets should be brought in for maintenance and/or whether new assets should be acquired.

The present method and/or system may be realized in hardware, software, or a combination of hardware and software. The present methods and/or systems may be realized in a centralized fashion in at least one computing system, or in a distributed fashion where different elements are spread across several interconnected computing or cloud systems. A typical combination of hardware and software may be a general-purpose computing system with a program or other code that, when being loaded and executed, controls the computing system such that it carries out the methods described herein.

Claim 1:
A welding asset tracking system (<NUM>), comprising:
an asset tag (<NUM>) retained by a first welding asset (200a), the asset tag (<NUM>) comprising asset data relating to the welding asset (200a);
a hub (<NUM>) retained by a second welding asset (200b), the hub (<NUM>) comprising:
a tag reader configured to obtain the asset data from the asset tag (<NUM>), and
hub communication circuitry (<NUM>) configured to transmit the asset data; and
a welding asset tracking server (<NUM>) configured to receive the asset data and update an asset tracking database (<NUM>) with the asset data,
wherein the hub communication circuitry (<NUM>) is further configured to transmit a location;
characterized in that the system (<NUM>) further comprises a local positioning system, the local positioning system comprising:
a plurality of location beacons (<NUM>) arranged in a grid configuration within a welding area (<NUM>), comprising:
memory circuitry (<NUM>) configured to store a beacon location, and
communication circuitry (<NUM>) configured to transmit a location signal representative of the beacon location; and
in that the hub (<NUM>) further comprises hub processing circuitry configured to determine a location using the local positioning system; and
in that the hub communication circuitry (<NUM>) is configured to receive the location signal, and the hub processing circuitry is configured to determine the location based on the beacon location.