Patent Description:
Welding is a process that has increasingly become ubiquitous in all industries. Conventional systems and methods for short circuit welding processes, such as welding, brazing, adhesive bonding, and/or other joining operations, require substantial investments in equipment, such as processing, displays, practice workpieces, welding tool(s), sensor(s), and/or other equipment.

Conventional welding systems and processes often require high power outputs, which may generate heat that compromises performance of the welding systems. In this regard, the welding systems may benefit from systems and methods that provide cooling for such components.

<CIT> describes an example of a portable plasma cutting system that includes a torch power unit, including a monitor and/or control configured to determine a temperature of a component. A fan may also be included inside the system to provide air circulation and cooling to the system. In addition compressed gas cools the torch. <CIT> describes an example of an air plasma cutting machine which comprises a machine box, a first air valve and a cooling air outlet port. A first branch of compressed air is connected with an air inlet end of the first air valve and a second branch of the compressed air is connected with a plasma cutting gun which is arranged outside the machine box. An air outlet end of the first air valve is connected with the cooling air outlet port which is arranged in the machine box. The cooling air outlet port faces heating parts in the machine box.

The present disclosure is directed to systems and methods with integrated compressed air cooling, substantially as illustrated by and/or described in connection with at least one of the figures, and as set forth in the claims. The invention is set out in the claims.

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 integrated compressed air cooling for welding systems. In particular, the disclosed systems and methods may employ compressed air to implement one or more welding processes (e.g., a gouging or cutting processes), with the compressed air being conveyed through such welding systems. In some examples, the compressed air is routed within the welding system to provide cooling for one or more components therein. For instance, components such as power conversion circuitry may heat up during the welding process. Routing compressed air near the components will introduce relatively cool air to the environment. As the passing compressed air heats in response to interaction with the heated components, heat is drawn from the components and/or the nearby environment. As a result, the components may operate more efficiently, in a greater variety of environments, with an extended useful life.

Welding power supplies and/or welding wire feeders are configured to operate 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)). In an example, 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 during a gouging operation. In some examples, the compressed air is routed through a connected welding system (e.g., a welding power source, a welding wire feeder) as the compressed air is conveyed to the gouging torch. The compressed air is typically cooler than components or air within a housing of the welding system. Thus, the compressed air may be channeled through the welding system to introduce cooling to the components and/or housing of the welding system, as well as move heated air away from the components and/or housing as the air is conveyed to the gouging torch.

Typical gouging processes operate with greater electrical current then a typical welding applications. Welding systems configured to perform gouging processes may employ a higher amperage capacity connection point (e.g., couplings, studs, outlets, etc.), conduction paths (e.g., wiring, cabling, a bus, etc.) and electrical components (e.g., control circuitry, power conversion circuitry, etc.). Such higher amperage capacity components increase both cost and weight of the welding system.

Compressed air is typically employed for gouging applications, such that if the compressed air were routed through the welding system it could be utilized to provide cooling for critical and/or heat sensitive components, which may allow for a lighter, more robust, and more cost-effective system design.

As compressed air is a feature of gouging applications, the structure by which the compressed air is conveyed can be rerouted and/or extended within the welding system while still supplying the gouge torch with the necessary amount of compressed air. For instance, the structure can include channels, conduits and/or tubing (e.g., flexible, rigid, or a combination of both), which may be arranged near a component, be designed to pass through a component, or cool a first element which provides secondary cooling (e.g., a heat sink, fan, etc.).

In some examples the channels or conduits are constructed of a conductive material that readily draws heat from the components (e.g., a metal, semiconductor, etc.). In some examples, the channels or conduits are encased in a medium (e.g., a fluid, which may be static or circulating) which enhances the cooling effect from the flow of compressed air.

In some examples, the channels or conduits are constructed of multiple channels or conduits, such that one or more of the cooling channels may be open and/or one or more of the cooling channels may be closed. One or more valves may be included to open and/or close a particular cooling channel, which may be activated automatically (e.g., in response to a sensor input and/or a control signal) and/or in response to a user input. This technique can focus cooling on particular components (e.g., power conversion circuitry), direct cooling at different locations about the components (e.g., at a first or second side of the component, between two or more components, etc.), and/or block the cooling channels such that compressed air is conveyed directly to the gouging torch.

In some examples, a control circuit may identify if a particular component is in use and/or if heat at that component (and/or at a given location within the housing) has exceeded a threshold temperature level. For example, a particular operation may be being performed (e.g., gouging) as well as an auxiliary function (e.g., battery charging, etc.), such that the control circuitry can operate the valves to direct compressed air to components and/or circuitry associated with the active operations. Further, one or more temperature sensors may be arranged at a component or given location in the housing. In response to a sensor measurement exceeding a threshold temperature value (e.g., one or more threshold temperature values), the control circuitry can operate the valves to direct compressed air to the associated component or location. Further, if the temperature value drops below the threshold temperature value (e.g., or another threshold temperature value), the control circuitry can operate the valves to direct compressed air away from the component or location.

Advantageously, the discloses systems and methods provide additional convenience over conventional systems, as a typical gouging torch has an electrical connection and a compressed air connection, thus having both connections at the welding system provides a convenient connection point, saving set up time. Weight of the system would also decrease, as the added cooling allows for the use of lighter components, resulting in a product that is easier for the operator to transport and use. Further, the added cooling allows for more cost effective components and a lesser need for replacement components, resulting in lower material and maintenance costs.

In disclosed examples, a welding system includes one or more channels within the welding system to convey compressed air from a compressed air source, a compressed air outlet to provide compressed air through the one or more channels to a gouging torch, and a cooling pathway to route compressed air through the one or more channels to a component within the welding system, wherein conveyance of the compressed air draws heat from the component.

In some examples, the one or more channels comprise a conductive material. In examples, the conductive material is one of a metal or a semiconductor. In some examples, the one or more channels comprise one or more of a flexible conduit or a rigid conduit. In examples, one or more valves selectively control conveyance of the compressed air to the one or more channels.

In some examples, one or more temperature sensors monitor temperature of the component. In examples, the component comprises one or more of a power conversion circuitry or a control circuitry. In some examples, the welding system comprises a welding power source or a wire feeder.

In examples, the welding system is configured to operate in a gouging mode or an arc welding mode, the compressed air source configured to activate in the gouging mode and deactivate in the arc welding mode. In some examples, the compressed air source is an air compressor. In examples, the one or more channels are located within a housing of the welding system.

In disclosed examples, a wire feeder includes one or more channels within the wire feeder to convey compressed air from a compressed air source, a compressed air outlet to provide compressed air through the one or more channels to a gouging torch, a cooling pathway to route compressed air through the one or more channels to a component within the wire feeder, wherein conveyance of the compressed air draws heat from the component, and one or more valves to selectively control conveyance of the compressed air to the one or more channels.

In some examples, one or more sensors monitor temperature of the component. In examples, a control circuitry is configured to receive signals from the one or more sensors corresponding to a temperature of the component, control the one or more valves to open to route compressed air to the component when the temperature has exceeded a first threshold temperature value, and control the one or more valves to close to prevent compressed air being routed to the component when the temperature is below the first threshold temperature value.

In examples, the one or more sensors are located on or near the component within the wire feeder. In examples, the torch includes a selector to control flow of compressed air to the torch. In some examples, a welding cable connects 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.

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> with integrated compressed air cooling. In some examples, the welding system <NUM> employs a compressed air source <NUM> (e.g., an air compressor) to output compressed air <NUM>. The compressed air <NUM> is used to implement one or more welding processes (e.g., a gouging or cutting processes). In some examples, the compressed air <NUM> conveyed through such welding systems to a gouging torch <NUM>, with some or all of the compressed air <NUM> routed within the welding system (e.g., a power source <NUM> and/or a wire feeder <NUM>) to provide cooling for one or more components therein (e.g., power conversion circuitry, etc.). Routing compressed air <NUM> near the components will introduce relatively cool air to the component and/or immediate environment, and as the passing compressed air heats in response to interaction with the heated components, heat is drawn from the components and/or the environment.

As shown in the welding system of <FIG>, the power supply <NUM> and the 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, compressed air, and/or 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 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>. Selection and activation of a gouging mode has been disclosed in <CIT>, entitled "Systems And Methods For Automatic Gouge Torch Activation".

In a gouging process, compressed air <NUM> is output from the compressed air source <NUM> to the gouging torch <NUM>. As gouging processes operate with greater electrical current then a typical welding applications, components and circuits to perform gouging processes may employ high amperage capacity connection point, conduction paths, and/or electrical components.

In the example of <FIG>, compressed air <NUM> output from the compressed air source <NUM> to torch <NUM> for gouging applications may be partially or completely routed through an alternative pathway or cooling channel <NUM> within the wire feeder <NUM> to provide cooling for critical and/or heat sensitive components, such as power conversion circuitry <NUM>. In some examples, the cooling channel <NUM> is designed to receive compressed air whenever the welding system <NUM> is operating in a gouging mode. In some examples, the cooling channel <NUM> may be selectively blocked (e.g., via a valve), such that compressed air is conveyed directly to the gouging torch <NUM>.

For instance, the cooling channel <NUM> can include one or more types of conduit, such as a flexible tube, a rigid tube, or a combination of both. The cooling channel <NUM> may be arranged near the power conversion circuitry <NUM>, be designed to pass through the power conversion circuitry <NUM> (e.g., a substrate, a gap in a PCB, between switches <NUM>, <NUM>, etc.), or pass through one or more heat sinks <NUM> (e.g., via a conductive tube) and/or cooling fluid from a fan, is the cooling channel <NUM> and/or the heat sink(s) <NUM> being cooled by the conveyed compressed air, then transferring cooling (e.g., through conduction, convection) to the power conversion circuitry <NUM>. In some examples, air can be directed to flow towards and/or near one or more heat sinks <NUM> (e.g., one or more fins), and/or heat producing components (e.g., circuitry), such as by a nozzle or tube comprised of and/or extending from the cooling channel <NUM>, for instance. Thus, the compressed air <NUM> can be rerouted and/or extended within the wire feeder <NUM> while still supplying the gouge torch <NUM> with the necessary amount of compressed air.

In an additional or alternative example, compressed air <NUM> 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 <NUM> can then be conveyed to the torch <NUM> via alternative tubing <NUM>. As shown, compressed air may be partially or completely routed through an alternative pathway or cooling conduit <NUM> within the power supply <NUM> to provide cooling for critical and/or heat sensitive components, such as power conversion circuit <NUM>. In some examples, the cooling conduit <NUM> is designed to receive compressed air whenever the welding system <NUM> is operating in a gouging mode and compressed air is being provided to the torch <NUM> via the power supply <NUM>. In some examples, the cooling conduit <NUM> may be selectively blocked (e.g., via a valve), such that compressed air is conveyed directly to the gouging torch <NUM> via alternative tubing <NUM>.

Compressed air <NUM> is not typically used for arc welding processes. However, if compressed air <NUM> is being used by an auxiliary system associated with the welding system <NUM>, the cooling systems and methods disclosed herein may be employed without the gouging mode being activated.

<FIG> illustrates another example wire feeder <NUM> providing multiple cooling channels <NUM>. In the example of <FIG>, compressed air <NUM> output to torch <NUM> for gouging applications may be routed through the wire feeder <NUM> to provide cooling for critical and/or heat sensitive components, such as power conversion circuitry <NUM>, control circuitry <NUM>, and/or wire drive <NUM> and associated components, as a list of non-limiting examples. For example, a series of couplers and/or valves <NUM> may control the path of the compressed airflow through the wire feeder <NUM>. In this manner, cooling channels <NUM> may be selected to direct cooling to one or more specific components or circuits, as well as provide different cooling profiles. For instance, a cooling channel <NUM> may encircle a component, thereby drawing heat from multiple surfaces of the component, as shown in <FIG>.

In some examples, one or more of the multiple cooling channels <NUM> may be open and/or one or more of the multiple cooling channels <NUM> may be closed. The valves <NUM> may be controlled to open and/or close a particular cooling channel, which may be activated automatically (e.g., in response to an input from a sensor <NUM> and/or a control signal from control circuitry <NUM>) and/or in response to a user input (from a user interface). This technique can focus cooling on particular components (e.g., power conversion circuitry <NUM>), and/or direct cooling at different locations about the components (e.g., at a first or second side of the component, between two or more components, etc.).

In some examples, the control circuitry <NUM> may identify if a particular component is in use and/or if heat at that component (and/or at a given location within the housing) has exceeded a threshold temperature level. For example, a particular operation may be being performed (e.g., gouging) as well as an auxiliary function (e.g., battery charging, etc.), such that the control circuitry <NUM> can operate the valves <NUM> to direct compressed air to components and/or circuitry associated with the active operations. In the example of a gouging operation, power conversion circuitry <NUM> and control circuitry <NUM> will be providing power and control, respectively, and the cooling channels <NUM> corresponding to these components may be open. However, the wire drive <NUM> will not be in use, so cooling of this component may be blocked.

In some examples, the sensor(s) <NUM> may be a temperature sensors (e.g., a thermistor, etc.) arranged at one or more of the components and/or at a given location in the housing. In response to a sensor measurement exceeding a threshold temperature value (e.g., one or more threshold temperature values), the control circuitry <NUM> can operate the valves <NUM> to direct compressed air to the associated component or location. For example, a first component (e.g., power conversion circuitry <NUM>) may have a higher temperature threshold than a second component (e.g., control circuitry <NUM>). Further, if the temperature value drops below the threshold temperature value (e.g., or another threshold temperature value), the control circuitry <NUM> can operate the valves <NUM> to direct compressed air away from the component or location.

Additionally or alternatively, the control circuitry <NUM> and/or control circuitry <NUM> adjusts one or more operational characteristics to optimize cooling from the compressed air. For example, data corresponding to component usage parameters (e.g., active time, amount of current during use, etc.) and/or temperature readings, may be collected over time (or input as a set of instructions) and stored on a memory accessible to a processor/control circuitry <NUM> associated with the power supply <NUM> and/or control circuitry <NUM> on wire feeder <NUM>. In such a case, the control circuitry can employ stored information (e.g., associated with a desired cooling profile, including historical data), and/or customizable information input by an operator (e.g., via an interface <NUM>) to route compressed air through one or more cooling channels.

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. 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 channels to provide optimum cooling for a given component, for a particular operation or parameter, etc..

<FIG> shows a flowchart representative of example machine readable instructions <NUM> which may be executed by the control circuitry <NUM> or <NUM> of <FIG> and <NUM> f to provide compressed air cooling in a welding type system. At block <NUM>, the system is controlled to operate in a gouging mode (such as via selector <NUM>, in response to a user input, and/or from a program sequencer). At block <NUM>, the control circuitry receives signals from one or more sensors (e.g., sensors <NUM>) corresponding to a temperature of a component (e.g., power conversion circuitry <NUM>). In block <NUM>, a temperature value or change in temperature value is compared to one or more threshold temperature values or change in values (e.g., stored in memory of control circuitry <NUM>, <NUM>). If the value or change in value does not exceed a first threshold value at block <NUM>, the method returns to block <NUM> to continue to receive sensor data.

If the value or change in value does exceed the first threshold value at block <NUM>, the method proceeds to block <NUM> to open a valve (e.g., valve <NUM>) to route the compressed air through a corresponding cooling channel (e.g., cooling channel <NUM>).

At block <NUM>, the control circuitry continues to monitor the sensor output and at block <NUM> a temperature value or change in temperature value is compared to the first threshold temperature value or change in value (or a second threshold value or change in value). If the value or change in value has not fallen below the first threshold value at block <NUM>, the method returns to block <NUM> to continue to receive sensor data. If the value or change in value does fall below the first threshold value at block <NUM>, the method proceeds to block <NUM> to close the valve to prevent the compressed air being routed through the corresponding cooling channel. The method then returns to block <NUM> to continue to operate in a gouging mode.

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

Claim 1:
A welding system (<NUM>) comprising:
one or more channels (<NUM>) within the welding system (<NUM>) configured to convey compressed air (<NUM>) from a compressed air source (<NUM>);
a compressed air outlet configured to provide compressed air (<NUM>) through the one or more channels (<NUM>) to a gouging torch (<NUM>); and
a cooling pathway configured to route compressed air (<NUM>) through the one or more channels (<NUM>) to a component within the welding system (<NUM>), wherein conveyance of the compressed air (<NUM>) is configured to draw heat from the component.