Patent ID: 12214439

DETAILED DESCRIPTION

FIG.1is a diagram of a fluid flow system100for cooling one or more components of a welding machine according to some embodiments. The system100is illustrated as being a resistance welding system, although embodiments described herein are not limited to any particular system or application. At least some of the embodiments described herein may be advantageously utilized in any fluid flow system in which it is desired to liquid cool component(s) and/or drawback fluid from one or more flow paths (or “passageways”).

The system100includes a resistance welding machine102having a hollow frame104which supports two vertically opposed welding electrodes106and108made of copper or other suitable material. The electrodes106and108may also be known as welding tips or caps. In operation, a work piece110, typically consisting of two or more metal sheets, can be clamped between the electrodes106and108and an electrical voltage can be applied across the electrodes106and108. This can cause a large electric current to flow from one of the electrodes106or108to the other through the work piece110, raising a temperature of the work piece110to a level which can result in localized melting and fusion of the individual sheets of the work piece110together.

Additionally, the high electric current passing through the electrodes106and108may cause them to melt if cooling means are not provided. For this reason, cooling fluid flow paths (e.g., paths212,214discussed below) can be provided which can extend from an inlet leading to a source of pressurized cooling fluid (e.g., water or other suitable fluid) through the apparatus114to fluid flow passageways in the frame104. Fluid can flow from the apparatus114through an inlet Y-connector116to upper and lower fluid inlets118and120of the frame104. Fluid can exit the frame104through upper and lower outlets122and124and an outlet Y-connector126and flows through the apparatus114to a fluid outlet and reservoir. In some embodiments, the apparatus114for the measurement and control of cooling fluid can be of the type commercially available from Proteus Industries, Inc. of Mountain View, Calif. under the trade name WELDSAVER™.

It will be noted that the arrangement ofFIG.1, as well as the following figures, are by way of examples and not meant to limit the scope of embodiments described herein. Other typical configurations include, for example, a series connection of upper and lower flow paths, in which case there are no Y-connectors. In addition, other devices such as transformers, power supplies and high current cables which need to be cooled may be inserted into the system100.

FIG.2Ais a diagram of a fluid flow system200for cooling welding electrodes202,204according to some embodiments. Such a system200can be used, for example, to cool electrodes of a resistance welding apparatus (e.g., welding machine102). In the illustrated embodiment, more specifically, liquid coolant206(e.g., water) can flow from a supply source208(e.g., one or more pumps, reservoirs, etc.) through welding electrodes202,204, e.g., of the type described above, via one or more fluid passageways. In the illustrated embodiment, the passageways form a loop which can be logically divided into fluid paths212,214. The liquid coolant206can be returned to the coolant source208or otherwise discharged via coolant return210.

As shown, liquid coolant206can flow through paths212,214, as indicated by arrows216, thereby cooling the electrodes202,204, e.g., to a temperature at which the electrodes202,204will not melt or their function be otherwise damaged by heat. Although two electrodes202,204and two corresponding fluid paths212,214are shown here, other embodiments may have a greater or lesser number of such electrodes and/or fluid paths. In some embodiments, the paths212,214may comprise flexible and/or rigid tubing.

The illustrated electrodes202,204may be detachably connected, e.g., to the frame104, by a press fitting or the like. One or both electrodes may detach from the welding machine. An electrode can detach for a variety of reasons, such as scheduled maintenance, damage to the electrode, or fusion of one or more of the electrodes to the work in progress. The latter may be especially prevalent when welding galvanized parts.

If either electrode202,204detaches, a large quantity of fluid206may spurt out of the fluid paths212,214(unless one or more embodiments as described herein are implemented). For example, if either electrode202,204detaches, fluid206may spray out of the resulting gap due to supply pressure, back pressure and/or gravity in the paths212,214. Spillage of fluid206, especially in an environment of high electrical current, as mentioned above, may be unsafe, wasteful, and may impact the work environment or damage equipment. Various embodiments described herein may reduce or eliminate fluid leakage.

FIG.2Bis a diagram illustrating fluid shutoff valves220,222for the fluid flow system200according to some embodiments. In some embodiments, flow of coolant206may be reduced or stopped, either in anticipation of electrode202,204detachment, e.g., for maintenance, or in response to an unintentional detachment of an electrode202,204, e.g., during a failure. More specifically, shutoff valve220can be used to reduce or stop coolant flow from the supply208, and shutoff valve222can be used to prevent backflow from the return210. For example, valve220can be a solenoid or pneumatically actuated valve, and the valve222can be a non-return check valve, although in other embodiments it may be otherwise.

FIG.2Cis a diagram illustrating detachment of the welding electrode202in conjunction with the fluid shutoff of the fluid flow system200according to some embodiments. Detachment of electrode202in conjunction with shutoff of the coolant supply208and return210can create a severed loop, open at two ends230,232, and filled with coolant206. With both ends230,232open to atmosphere, a gap236is formed and coolant206may readily escape.

In some embodiments, upon detachment of a welding electrode, e.g., welding electrode202, the shut off valves220and/or222may be actuated thereby shutting off flow of fluid through fluid pathways212and214. By shutting off the flow of fluid, fluid loss caused by the detached welding electrode202may be reduced.

It will be appreciated that the shut off values220and/or222may detect detachment or be commanded to actuate in any number of ways. For example, the shut off valves220and/or222may shut off fluid flow upon detection of a change in pressure or other fluid flow conditions. In another example, the shut off valves220and/or222may be in communication with a sensor that detects if the welding electrode202becomes detached, e.g., through electrical communication with the welding electrode202. The sensor may send commands to one or both shut off valves220and222to shut off flow of fluid. In a further example, the shut off valves220and222may be commanded to shut off the flow of fluid by a robotic automation system or worker at the fluid flow system200, e.g., electronically in a manner similar to the sensor or mechanically. In yet another example, the shut off valves220and/or222may shut off if the flow of fluid stops in either fluid pathway212or214.

FIG.3Ais a diagram of a fluid flow system300for cooling welding electrodes302,304including a fluid drawback apparatus340according to some embodiments. As shown, the system300includes welding electrodes302and304, coolant supply308, fluid passageway312,314, coolant return310, shutoff valves320,322and drawback apparatus340. It will be appreciated that the features of system300may be the same or different from the corresponding features discussed herein (e.g., welding electrodes202,204, shutoff valves220,222, welding electrodes502,504, and the like).

The illustrated drawback apparatus340includes a drawback chamber (e.g., a cylinder)342and a drawback piston346disposed therein. Movement of the piston346can create a suction force that may draw coolant306from the passageway312,314into the cylinder342when, for example, either electrode302or304is at least partially detached. Further description of the drawback apparatus340in various configurations can be found below. It will be appreciated that the drawback apparatus340may be coupled to the supply line350as illustrated, or to the return line352.

In one example, the drawback apparatus340may draw coolant306from passageway312and/or314if electrode302and/or electrode304are detached. The drawback of the coolant306by the drawback apparatus340may draw the fluid306away from any breaks or gaps in the passageway312and/or314. In some embodiments, the drawback apparatus340may draw fluid, e.g., coolant306, at the same time or approximately when the shutoff valves320and/or322shut off fluid flow. For example, the drawback apparatus340may create a suction for drawing back coolant306immediately preceding the removal of either electrode302,304for routine or scheduled maintenance.

FIG.3Bis a diagram of the fluid drawback apparatus340evacuating (or “drawing back”) coolant306according to some embodiments. The drawback apparatus340can be employed to drawback coolant306from the fluid passageway312to prevent or reduce coolant306escape from a gap336that is formed when the welding electrode302detaches (seeFIG.3A). The gap336can be an air gap, or other vent to atmosphere. Although the electrode302is shown fully detached, it will be appreciated that the drawback apparatus340can be employed when any gap is formed, e.g., when the electrode302partially detaches or when the pathways312and/or314are broken.

As shown, the drawback apparatus340is placed on fluid supply line (or “path” or “segment”)350in order to intersect the passageway at a point which divides the passageway312into a short segment312bon one side of the gap336and the passageway314plus a part of the passageway312into a long segment314bon the opposite side of the gap336. It will be appreciated that “segments” can also be referred to as “paths.”

In other embodiments, the drawback apparatus340can be placed on fluid return line (or “path” or “segment”)352in addition to, or instead of, on the supply line350. In the illustrated embodiment, the drawback apparatus340can have a liquid volume capacity sufficient to evacuate all of the coolant206from the passageways(s)312,314. For example, the volume capacity can be 250 cc. Drawing back the coolant306by the coolant drawback apparatus340draws coolant306away from the gap336thereby preventing or reducing coolant306loss. In some embodiments, evacuating the short segment312bcan create a vent to atmosphere on the long segment314b, thereby preventing or reducing any further coolant306removal. In various embodiments, the coolant drawback apparatus340draws coolant306back after the shut off valves320and322362have shut off flow of coolant306.

In some embodiments, as illustrated inFIG.3C, the system300may include one or more additional shutoff valves360and/or362(e.g., non-return check valves) positioned along the fluid passageways312,314. For example, valve360may be positioned at an outlet of passageway312and valve362may be positioned at an outlet of passageway314. Depending upon their placement and number, valves360and/or362may eliminate the necessity of valves320and/or322, e.g., as shown by omission of valve322. The valves360,362, may be shut off automatically (e.g., by an actuator, computer, or the like) or manually (e.g., by an operator) at the same or approximately same time as the valves320,322. Such a configuration may, for example, reduce and/or prevent liquid spillage from passageways312,314when the electrodes302,304are at least partially detached, by blocking the possible vent to atmosphere on the long segment314b. This may leave a segment312cwithout coolant drawback from the gap336when electrode302is detached as shown, but, in some embodiments, the typically small geometries of the passageways adjacent to the electrodes may allow for surface tension of the coolant to prevent substantial spillage. It will appreciated that although two additional valves360,362are shown here, in other embodiments, a greater or lesser number of such valves may be used, and/or positioned elsewhere on passageways312,314.

FIG.4is a flowchart illustrating an example operation of a fluid drawback apparatus (e.g., drawback apparatus340as shown inFIGS.3A and3B) according to some embodiments. It will be appreciated that although the steps402-408below are described in a specific order, the steps402-408may also be performed in a different order. Each of the steps402-408may also be performed sequentially, or serially, and/or in parallel with one or more of the other steps402-408. For example, step402can be performed simultaneously or nearly simultaneously (i.e., in parallel or nearly in parallel) with step404. In some embodiments, operation of the drawback apparatus may include a greater or lesser number of such steps.

In step402, a first welding electrode (e.g., welding electrode302) is cooled by circulating liquid coolant (e.g., coolant306) through a first liquid coolant path (e.g., path312) in fluid coupling with the first welding electrode. More specifically, a coolant supply (e.g., supply308) may supply liquid coolant to the first liquid coolant path via a supply line (e.g., supply line350). Since the first welding electrode is included in the first coolant path, the first electrode is cooled by the circulating liquid.

In step404, a second welding electrode (e.g., welding electrode304) is cooled by circulating liquid coolant (e.g., liquid coolant306) through a second liquid coolant path (e.g., path314) in fluid coupling with the second welding electrode. More specifically, a coolant supply (e.g., supply308) can supply liquid coolant to the second liquid coolant path via a supply line (e.g., supply line350). Since the second welding electrode is included in the second coolant path, the second electrode is cooled by the circulating liquid.

Although in the illustrated embodiment the first and second paths are supplied coolant by the same source (e.g., supply308), in other embodiments they may be supplied by different sources (e.g., supply308and a separate supply source). For example, each path may be separate from each other and/or each path may include one or more separate coolant supplies.

In step406, flow of liquid coolant through the first liquid coolant path is stopped or reduced when the first electrode at least partially detaches. A shutoff valve (e.g., valve320) positioned on the supply line can be manually (e.g., by a human operator) or automatically triggered (e.g., by an actuator, computer, or the like), either in anticipation of, or response to the electrode at least partially detaching. As discussed above, the electrode can detach for a variety of reasons including, but not limited to, a scheduled maintenance or a failure, e.g., melting and/or fusion of the electrode to the work in progress (e.g., work piece110).

In step408, the liquid coolant is drawn back from a gap (e.g., gap336) in the first liquid coolant path that is formed when the first welding electrode at least partially detaches. For example, a drawback apparatus (e.g., drawback apparatus340) can create a suction (e.g., via movement of piston346) that draws the coolant away from the gap and into a chamber (e.g., chamber342). The coolant may be drawn back from the gap on either or both sides of the path to the gap.

FIG.5Ais a diagram of a fluid flow system500for cooling welding electrodes502,504including independent fluid shutoff for individual fluid path segments512a-bof a fluid path512according to some embodiments. Isolating electrode502with independent shutoff valves520,522may eliminate the problem of a severed loop with both ends vented to atmosphere when electrode502is at least partially detached. Instead, individual path segments512a-b(or “line segments”) may be formed, each open at only one end. In the illustrated embodiment, the valves520,522can each be a solenoid or pneumatically actuated valves, a non-return check valve, or otherwise.

It will be appreciated that the features of system500may be the same or different from the corresponding features discussed herein (e.g., welding electrodes202,204, shutoff valves220,222, welding electrodes702,704, or the like). It will be further appreciated that althoughFIG.5Ais described here with respect to fluid path512, the discussion herein can also apply to one or more other fluid paths, e.g., fluid path514.

In some embodiments, shutoff valves520and522may isolate segment512a-bfrom the rest of the system500thereby shutting off fluid from the coolant supply508and the coolant return510. The shutoff valves520and/or522may be controlled (e.g., electrically) or be mechanical. The shutoff valves520and/or522may be actuated or triggered to shut off fluid flow to and/or from the segment512a-bwhen the electrode502is removed and/or in anticipation of removal. In some embodiments, there may be a limited leakage of coolant out the gap formed by full or partial removal of the electrode502. In some embodiments, loss of coolant out the gap is limited because of air pressure from the atmosphere and/or surface tension of the coolant in the segment512a-b.

FIG.5Bis a diagram illustrating a drawback apparatus540for providing independent fluid506removal (or “drawback”) for each of the path segments512a-baccording to some embodiments. As shown, the drawback apparatus540includes four drawback elements542-548, each positioned on a portion (or “segment”) of fluid path512or514. More specifically, drawback element542is positioned on portion512a; drawback element544is positioned on portion512b; drawback element546is positioned on portion514a; and drawback element548is positioned on portion514b.

In the illustrated embodiment, each of the drawback elements542-548may have the same configuration and/or operation as the drawback apparatus340discussed above. Thus, for example, each of the drawback elements542-548may include a piston542a-548adisposed within a chamber542b-548b. In the other embodiments, they can each have a different configuration and/or operation, e.g., such as the configuration and/or operation of drawback valve800or1000, discussed herein.

FIG.5Cis a diagram illustrating a drawback fluid flow when a welding electrode502is detached, or partially detached, from the fluid flow system500according to some embodiments. Generally, for coolant passageways (e.g., fluid path512) of sufficiently small cross-sectional area, surface tension largely reduces the amount of coolant that may escape from each isolated path (e.g., path512a-b), and thus the volume capacity of the drawback apparatus540may be limited. For example, the total combined volume of four independent drawbacks elements542-548may be substantially less than the previous single drawback apparatus340.

In some embodiments, when an electrode is detached and a gap formed along path512, the shutoff valves520and522may engage to stop flow of coolant along the segment512a-b. One or both drawback elements542and544may drawback fluid from the segment512a-b. Since the shutoff valves520and522do not allow for coolant to be brought to segment512a-b, the coolant may be drawn away from the gap, e.g., drawback element542may draw coolant back from the gap along segment512aand drawback element544may draw coolant back from the gap along segment512b.

Coolant may continue to flow along path514even if shutoff valves520and522have engaged. In one example, the coolant along path514continues to flow to reduce temperature of the other electrode.

Although no shutoff valves are shown along path514, it will be appreciated that there may be no shutoff valves or one or more shutoff valves, e.g., forming a segment of path514.FIG.5Dis an illustration of this example.

FIG.5Dis a diagram illustrating a drawback fluid flow when both welding electrodes502,504are at least partially detached from the fluid flow system500according to some embodiments. By including independent shutoff valves520-526and drawback elements542-548for each path segment512a-band514a-b, both electrodes502,504can be detached at once, even simultaneously (or near simultaneously), with no or reduced coolant loss.

The drawback apparatus540or, more specifically, each of the drawback elements542-548, may drawback coolant506away from the gaps533,534formed when the welding electrodes502,504at least partially detach. The arrows550-553indicate directions away from the gaps533,534the coolant can be drawn.

FIG.6is a flowchart illustrating an example operation of a fluid drawback apparatus (e.g., drawback apparatus540) according to some embodiments. It will be appreciated that although the steps602-616below are described in a specific order, the steps602-616may also be performed in a different order. Each of the steps602-616may also be performed sequentially, or serially, and/or in parallel with one or more of the other steps602-616. For example, steps602-608can be performed simultaneously (i.e., in parallel) with steps610-616. In some embodiments, operation of the drawback apparatus may include a greater or lesser number of such steps.

In step602, a first welding electrode (e.g., electrode502) is cooled by liquid coolant (coolant506) circulating through a first liquid coolant path (e.g., path512) in fluid coupling with the first welding electrode. In some embodiments, a coolant supply (e.g., supply508) may supply the liquid coolant to the first path. The liquid coolant may be water, but as discussed above, it can be any fluid (e.g., combination of chemicals and/or liquids). The circulating liquid coolant may cool the first welding electrode to a temperature to reduce or prevent a failure, e.g., melting, fusing to a work piece (e.g., work piece110), or the like.

In step604, flow of the liquid coolant through the first liquid coolant path is stopped or reduced when the first welding electrode at least partially detaches. For example, when the first welding electrode at least partially detaches, e.g., in response to a failure or maintenance, the shutoff valves (e.g., valves520,522) may stop or reduce flow of the liquid coolant to and/or through the first fluid path (or portions thereof, e.g., portion514a-b). As discussed above, activation of the shutoff valves may occur manually (e.g., by an operator) or automatically (e.g., by one or more actuators, a computer, etc.).

In step606, the liquid coolant is drawn back (e.g., by one or more drawback apparatuses540) in a first direction away from a gap formed in the first liquid coolant path when the first welding electrode at least partially detaches. For example, a first drawback element (e.g., drawback element542) may draw the coolant away from the gap and into the first element. Movement of a drawback piston (e.g., piston542a) may create a suction that draws coolant away from the gap and into a drawback chamber (e.g., chamber542b).

In step608, liquid coolant is drawn back in a second direction away from the gap formed in the first liquid coolant path when the first welding electrode at least partially detaches. For example, a second drawback element (e.g., drawback element544) may draw the coolant away from the gap and into the second drawback element. Movement of a drawback piston (e.g., piston544a) can create a suction that draws coolant away from the gap and into a drawback chamber (e.g., chamber544b). Steps606and608may occur simultaneously or nearly simultaneously.

In step610, a second welding electrode (e.g., electrode504) is cooled by the liquid coolant circulating through a second liquid coolant path (e.g., path514) in fluid coupling with the second welding electrode. In some embodiments, the coolant supply can supply the liquid coolant to the second path. The circulating liquid coolant may cool the second welding electrode to a temperature to reduce or prevent a failure, e.g., melting, fusing to a work piece (e.g., work piece110), or the like.

In step612, flow of the liquid coolant through the second liquid coolant path is stopped or reduced when the second welding electrode at least partially detaches. For example, when the second welding electrode at least partially detaches, e.g., in response to a failure or maintenance, the shutoff valves (e.g., valves524,526) may stop or reduce flow of the liquid coolant. The valves524,526may stop or reduce flow of coolant to and/or through the second path (or portions thereof, e.g., portion514a-b). As discussed above, activation of the shutoff valves may occur manually (e.g., by an operator) or automatically (e.g., by a computer, actuator(s), etc.).

In step614, the liquid coolant is drawn back in a first direction away from a gap formed in the second liquid coolant path when the second welding electrode at least partially detaches. For example, a third drawback element (e.g., drawback element546) may draw the coolant away from the gap and into the third element. Movement of a drawback piston (e.g., piston546a) may create a suction that draws coolant away from the gap and into a drawback chamber (e.g., chamber546b).

In step616, liquid coolant is drawn back in a second direction away from the gap formed in the second liquid coolant path when the second welding electrode at least partially detaches. For example, a fourth drawback element (e.g., drawback element544) may draw the coolant away from the gap and into the fourth element. Movement of a drawback piston (e.g., piston548a) may create a suction that draws coolant away from the gap and into a drawback chamber (e.g., chamber548b).

It will be appreciated that although the same liquid coolant (e.g., coolant506) flows through both the first and second liquid coolant paths in the illustrated embodiment, different liquid coolant (e.g., liquid coolant supplied from different sources and/or liquid coolant of different types) may flow through each of the first and second liquid coolant paths in other embodiments.

FIG.7Ais a diagram of a fluid flow system700for cooling welding electrodes702,704including a drawback valve apparatus740according to some embodiments. As shown, valves for each electrode can be included within a drawback apparatus (e.g., drawback apparatus540) to create the drawback valve apparatus740.

It will be appreciated that the features of system700may be the same or different from the corresponding features discussed above (e.g., welding electrodes202,204, shutoff valves220,222, or the like.). Accordingly, the drawback elements742-748may have a same or similar configuration and/or operation as the drawback elements542-548described above. Likewise, the valves720-724may also have a same or similar configuration and/or operation as the valves520-524described above, although in other embodiments, the valves720-724may be included within the drawback elements740-746.

InFIG.7A, coolant supply708provides coolant706along paths712and714to cool welding electrodes702and704, respectively. The coolant706is then received by coolant return710(where the coolant706, in some embodiments, may be recirculated). The system700may include shutoff valves720and722that may shut off flow of the coolant706along the path712(e.g., if a gap or a break occurs in the path712, or preceding the planned removal of an electrode702). Similarly, the system700may include shutoff valves724and726that may shut off flow of the coolant706along the path714. Drawback elements742and744may draw coolant706into the drawback elements742and744, respectively, if a gap or break forms in the path712. Similarly, drawback elements746and748may draw coolant706into the drawback elements746and748, respectively, if there is a gap or break in the path714.

In the example depicted inFIG.7A, both paths712and714receive coolant706from the coolant supply708along, at least partially, the same path (i.e., the paths form a loop including a partially shared path from the coolant supply708). Similarly, both paths712and714provide coolant706to the coolant return710along, at least partially, the same path.

In various embodiments, the drawback element742will be disposed between a shutoff valve (e.g., shutoff valve720) and the electrode702. Similarly, the drawback element744may be disposed between a shutoff valve (e.g., shutoff valve722) and the electrode702. The drawback element746may be disposed between a shutoff valve (e.g., shutoff valve724) and the electrode704. The drawback element748may be disposed between a shutoff valve (e.g., shutoff valve726) and electrode704.

In various embodiments, upon detection of a break or gap in or along the path712(e.g., caused by a breach of the system and/or detachment of a welding electrode702), the shutoff valve720and the shutoff valve722may activate to block flow of coolant706from the coolant supply708and block backflow of coolant706from the coolant return710, respectively.

The drawback element742may not activate until the shutoff valve720has shut off flow of the coolant706. In some embodiments, the drawback element742will not activate until both the shutoff valves720and722have shut off flow of the coolant706. Once active, the drawback element742may draw fluid away from the gap or break by pulling coolant706into a reservoir (e.g., a chamber within the drawback element744).

Similarly, the drawback element744may not activate until the shutoff valve722has shut off flow of the coolant706. In some embodiments, the drawback element744will not activate until both the shutoff valves720and722have shut off flow of the coolant706. Once active, the drawback element744may draw fluid away from the gap or break by pulling coolant706into a reservoir (e.g., a chamber within the drawback element744).

Once the gap or break is corrected, the shutoff valves720and722may be opened to allow flow of coolant706. In some embodiments, the drawback elements742and/or744may push the coolant706from their respective reservoirs back into the paths.

It will be appreciated that one or more shutoff valves may be optional. For example, the coolant supply708may be configured to shut itself off if a break or gap in the path of the system700is detected. The coolant supply708may shut itself off such that little or no coolant706may leak into the paths from the coolant supply708even if the drawback elements742,744,746, and/or748draw coolant706away from the paths (e.g., in the case of a break or gap). Similarly, the coolant return710may shut itself off such that little or no coolant706may leak into the paths from the coolant return710even if the drawback elements742,744,746, and/or748draw coolant706away from the paths.

FIG.7Bis a diagram illustrating a drawback valve apparatus740operated by a single actuator770according to some embodiments. More specifically, the drawback valves720-724and drawback elements742-748, and components thereof (e.g., piston, or the like.) are operated by the actuator770. Although actuator770is shown here operating four valves722-724and drawback elements742-744, in other embodiments the actuator770may operate a greater or lesser number of such valves and/or drawback elements. The actuator770may be a pneumatic actuator or may be otherwise (e.g., electric, hydraulic, mechanical, etc.). It will be appreciated that there may be any number of actuators.

In various embodiments, each shutoff valve720,722,724, and/or726may share one or more actuators (or may each be associated with a separate actuator). The actuator may be coupled to any number of sensors for detecting breaks or gaps in paths of the system700. If a break or gap is detected, any number of actuators may control any number of shutoff valves to shut off flow of coolant706. Alternately, in some embodiments, the actuator(s) are mechanically controlled (e.g., through a worker).

In some embodiments, upon sensing a break, the actuator(s) may control a subset of shutoff valves. For example, if a breach in the path712is detected (e.g., from detachment of the electrode702), the actuator(s) may activate shutoff valves720and/or722to shut off coolant706flow. If a breach in the path714is detected (e.g., from detachment of the electrode704), the actuator(s) may activate shutoff valves724and726) to shut off coolant706flow.

In some embodiments, the actuator(s) may control drawback elements (e.g., drawback elements742-748). For example, after the shutoff valves720and722shut off flow of coolant706, the actuator(s) may control the drawback elements742,744,746, and/or748. The actuator(s) may control a subset of the drawback elements. For example, after detecting a breach in the path712, the actuator(s) may control the drawback elements742and/or744to drawback coolant706from the paths (e.g., from the breach). Upon detection or a command that the breach has been corrected (e.g., the welding electrode702has been replaced), then the actuator(s) may control the drawback elements742and/or744to push the coolant back to the paths. Similarly, after detecting a breach in the path714, the actuator(s) may control the drawback elements746and/or748to drawback coolant706from the paths (e.g., from the breach). Upon detection or a command that the breach has been corrected, then the actuator(s) may control the drawback elements746and/or748to push the coolant back to the paths.

FIG.7Cis a diagram illustrating a drawback valve apparatus750operated by multiple actuators770,772according to some embodiments. Generally, more than one actuator may be employed if independent coolant control is desired for each electrode702,704. As shown, actuator770may control cooling for the first welding electrode702, and actuator772controls cooling for the second welding electrode704. In some embodiments, the actuator770operates valves720,722and drawback elements742,744, and actuator772operates valves724,726and drawback elements746,748. Although each actuator770,772is shown here operating two valves and drawback elements, in other embodiments they may each operate a greater or lesser number of such valves and/or drawback elements. Additionally, other embodiments may include a greater number of such actuators. In the illustrated embodiments both actuators770,772are pneumatic actuators but in different embodiments it can be otherwise.

FIG.8Ais a diagram of a drawback valve800shown in a first position (e.g., an “open” position) according to some embodiments. In the illustrated example, the drawback valve800includes a valve element802(e.g., a diaphragm), a spring804, a piston810, and a holdback pin814, all incorporated into a drawback chamber816(e.g., a cylinder). Coolant may be provided by a coolant supply808.

As shown, the spring804can be pressed against, or coupled to, the valve element802on one side of the spring, and pressed against, or coupled to, an inside portion of the chamber816on an opposite side of the spring804. Such valve element and spring arrangements can be used in typical non-return check valves, but in this embodiment, the valve element802and spring804are biased against the normal flow of coolant from supply808to the welding electrode (e.g., electrode702or704). In operation, the valve element802can be forced open by a feature of the drawback piston810(i.e., holdback pin814), allowing coolant806to flow to the electrode through liquid coolant path812with chamber opening818serving as the coolant inlet, and chamber opening820serving as the coolant outlet. Flow of the coolant806is shown by directional arrows822from inlet to outlet. In some embodiments, the holdback pin814may be a feature of the valve element802, which may likewise be forced open by the piston810.)

Although the valve element802is depicted as flat, the valve element802may be any shape to assist and/or control the flow of coolant. For example, the valve element802may be angled, concave, or any shape. Similarly, the piston810may be any shape.

It will be appreciated that the drawback valve800may be configured as a normally biased non-return valve in the outflow path of an electrode to close upon a breach or gap at the electrode. For example, the normal flow of coolant in the opposite direction from that shown inFIG.8A(e.g., with chamber opening818serving as the coolant inlet and chamber opening820serving as the coolant outlet) may keep the valve element in the open position. A breach or gap in the inlet path may reduce pressure of the fluid allowing the spring and/or fluid backpressure to push the valve element802into the closed position in conjunction with actuation of the piston for drawback of coolant.

FIG.8Bis a diagram of the drawback valve800shown in a second position (e.g., a “closed” position) according to some embodiments. When actuated, e.g., by actuator770or772, the initial movement of the piston810releases the valve element802, allowing the spring804force and supply808pressure to force it closed, thus stopping or reducing the flow of coolant806to the electrode. In some embodiments, the drawback valve800may mechanically close from the open position (e.g., by coolant pressure, electrical control, or mechanical control).

FIG.8Cis a diagram of the drawback valve800shown in a third position (e.g., a “drawback” position) according to some embodiments. The remaining stroke of the piston810draws coolant806back from the electrode through opening820and into the chamber816with coolant flow through opening818blocked by the closure of valve element802. For example, in some embodiments, the piston810may draw coolant806from opening820serving as the coolant outlet of the valve800(e.g., as indicated by directional arrows824), with the valve element802closed to block the supply of coolant from opening818. In some embodiments, the direction of flow may be reversed and the piston810may draw coolant806from opening820serving as the coolant inlet of the valve800, with the valve element802acting as a normally biased non-return check valve that is closed by spring and/or fluid backpressure to block the backflow of coolant from opening818.

FIG.8Dis a diagram of a drawback valve800having a different configuration. In some embodiments, instead of, or in addition to, the diaphragm802, the drawback valve800may include a drawback valve element802a. For example, as shown, the drawback valve element802amay comprise a needle-shaped drawback valve element. It will be appreciated that other types and configurations of the drawback apparatus800may be implemented with the methods described herein.

It will be appreciated that the diagram of the drawback valve800, as shown inFIGS.8A-D, is shown in an example position relative to the welding electrode. More specifically, the valve800is depicted in a “left” (or, upstream) position relative to the welding electrode. For example, drawback element742is shown in a left position relative to the electrode702. Accordingly, as described above, liquid coolant806is drawn back into the drawback valve800through opening820. In some embodiments, the valve800may also be placed in different positions relative to the electrode, e.g., in a “right” (or, downstream) position relative to the welding electrode. For example, drawback element744is shown in a right position relative to the electrode702. In such a configuration, the valve800would be flipped in order to have the opening820on the left side of the diagram of the valve800(i.e., as opposed to the right side, as currently shown) in order to draw back liquid coolant806from the electrode through that opening820.

FIG.9is a flowchart illustrating an operation of a drawback valve (e.g., valve800) according to some embodiments. It will be appreciated that although the steps902-916below are described in a specific order, the steps902-916may also be performed in a different order. Each of the steps902-916may also be performed sequentially, or serially, and/or in parallel with one or more of the other steps. In some embodiments, operation of the drawback apparatus may include a greater or lesser number of such steps.

In step902, liquid coolant (e.g., coolant806) flowing through a liquid coolant path (e.g., path812) for cooling a welding electrode (e.g., electrode702) is received in a drawback chamber (e.g., chamber816). For example, the liquid coolant is received in the chamber one or more chamber openings (e.g., chamber opening818).

In step904, the coolant is permitted to flow through the liquid coolant path when a valve element (e.g., valve element802), disposed within the drawback chamber, is in an open position, thereby cooling the welding electrode. For example, the valve element can be in the open position when the valve element is forced open by a feature of a drawback piston (e.g., piston814), namely, a holdback pin (e.g., holdback pin814). In some embodiments, the valve element may be pushed open because the force generated by the piston is greater than the force generated by an opposing spring (e.g., spring804) and/or fluid pressure.

In step906, flow of the liquid coolant through the liquid coolant path is reduced or stopped when the valve element is in a closed position. The valve element can move to the closed position in response to a signal from an actuator (e.g., actuator770) when the welding electrode at least partially detaches.

In step908, liquid coolant is drawn back away from a gap in the liquid coolant path that is formed when the welding electrode at least partially detaches. For example, movement of the drawback piston can create a suction that draws coolant away from the gap and into the chamber, and stored at least temporarily therein (step910).

Although operation of a single drawback valve is described here, it will appreciated that embodiments of the present invention can include operation of multiple such valves, operating in parallel with each other or sequentially.

FIG.10Ais a diagram of a drawback valve1000in a first position (e.g., an “open” position) according to some embodiments. In the illustrated example, the drawback valve1000includes a valve element1002(e.g., a diaphragm), a spring1004, and a piston1016that may travel through a piston chamber1028.

As shown, the spring1004can be pressed against, or coupled to, the valve element1002on one side of the spring, and pressed against, or coupled to, an inside portion of the drawback valve1000on an opposite side of the spring1004. In some embodiments, this valve element and spring arrangements may be used as in typical non-return check valves. In some embodiments, the valve element1002and spring1004are biased against the normal flow of coolant from a coolant supply (e.g., supply708) to the welding electrode (e.g., electrode702or704).

In operation, the valve element1002may be forced open by the piston1016. In some embodiments, the piston1016may push on a valve element actuator member1018coupled to the valve element1002, thereby allowing coolant (e.g., coolant706) to flow to the electrode through liquid coolant paths1012,1014and drawback valve openings1020,1022, e.g., as indicated by directional arrows1024. In various embodiments, the piston1016may push directly on the valve element1002to allow coolant flow through the paths1012,1014and openings1020,1022. In some embodiments, coolant may also flow in the opposite direction with the valve element acting as a normally biased non-return check valve.

In some embodiments, movement of the piston1016(e.g., as indicated by directional arrows1026) may be effected by one or more actuators (e.g., actuator770) controlling a piston support member1028(e.g., piston rod, piston shaft, etc.) coupled to the piston1016. In other embodiments, one or more actuators may directly control the piston1016itself, i.e., without a piston support member1028, e.g. direct hydraulic or pneumatic actuation of the piston, electromagnetic control of the piston, etc.

Although the valve element1002is depicted as flat, the valve element1002may be any shape to assist and/or control the flow of coolant. For example, the valve element1002may be angled, concave, or any shape. Similarly, the piston1016may be any shape.

FIG.10Bis a diagram of a drawback valve1000in a second position (e.g., a “closed” and/or “drawback” position) according to some embodiments. When actuated, e.g., by actuator770or772, initial movement of the piston1016releases the valve element802, and the spring804and/or fluid pressure pushes it closed, thus stopping or reducing the flow of coolant to the electrode. For example, the actuator could automatically trigger in response to a break or gap detected by one or more sensors, e.g., in the event of a failure. Alternatively, the actuator may be manually or mechanically controlled, e.g., by an operator in order to perform scheduled maintenance.

In some embodiments, the stroke of the piston1016, e.g., as indicated by arrows1018, may also draw coolant back from the electrode, or gap in the event of a breach, through opening1022and into a reservoir1030, e.g., as indicated by directional arrows1032. For example, the reservoir1024can have a liquid volume capacity sufficient to evacuate all of the coolant from the passageways(s), or a capacity sufficient to ensure evacuation of only the electrode. In some embodiments, liquid from the reservoir1030may be pushed back into the passageways by movement of the piston1016, e.g., once the breach has been repaired or scheduled maintenance completed.

It will be appreciated that the drawback valve1000may be configured as a normally biased non-return valve in the outflow path of an electrode to close upon a breach or gap at the electrode. In this case, for example, the flow of coolant may keep the valve element in the open position. A breach or gap in the path may reduce pressure of the fluid allowing the spring and/or fluid backpressure to push the valve element1002into the closed position in conjunction with actuation of the piston for drawback of coolant.

FIG.11is a diagram of a fluid flow system1100for cooling welding electrodes1102,1104including independent fluid shutoff and drawback for preventing or reducing liquid loss, e.g., during system1100maintenance.

It will be appreciated that some of the features of system1100may be the same or different from the corresponding features discussed above (e.g., welding electrodes202,204, shutoff valves220,222, or the like). Accordingly, drawback apparatus (or “drawback master”)1140may have the same or similar configuration as drawback apparatus340, and/or the valves1120-1128may have a same or similar configuration and/or operation as the valves520-524described above, although in other embodiments, the valves1120-1128may be included within respective drawback apparatus1140and/or drawback elements (or “drawback slaves”)1142-1148.

InFIG.11, a coolant supply1108provides liquid coolant1106to paths1112and1114, via supply path1150, to cool welding electrodes1102and1104, respectively. The coolant1106may then be received by a coolant return1110(where the coolant1106, in some embodiments, may be recirculated) via a return path1152. The system1100may include a “master” valve1120that may shut off flow of the coolant1106to the paths1112,1114(e.g., if a gap or a break occurs in the path1112and/or1114, or preceding the scheduled removal of an electrode1102and/or1104). Similarly, some embodiments may include shutoff valves1122and1124that may shut off flow of the coolant1106along the path1112(e.g., if a gap or a break occurs in the path1112, or preceding the planned removal of an electrode1102). In some embodiments, the system1100may also include shutoff valves1126and1128that may shut off flow of the coolant1106along the path1114. The drawback elements1142and1144may draw coolant1106into the drawback elements1142and1144, respectively, if a gap or break forms in the path1112. Similarly, the drawback elements1146and1148may draw coolant1106into the drawback elements1146and1148, respectively, if there is a gap or break in the path1114.

In some embodiments, shutoff valves1122and1124may isolate fluid path segments1112a-bfrom the rest of the system1100. The shutoff valves1122and/or1124may be controlled (e.g., electrically) or be mechanical. The shutoff valves1122and/or1124may be actuated or triggered to shut off fluid flow to and/or from the segment1112a-bwhen the electrode1102is removed and/or in anticipation of electrode1102removal (e.g., for scheduled system100maintenance).

Similarly, in some embodiments, shutoff valves1126and1128may isolate fluid path segments1114a-bfrom the rest of the system1100. The shutoff valves1126and/or1128may be controlled (e.g., electrically) or be mechanical. The shutoff valves1126and/or1128may be actuated or triggered to shut off fluid flow to and/or from the segment1114a-bwhen the electrode1104is removed and/or in anticipation of electrode1102removal (e.g., for scheduled system100maintenance).

In various embodiments, the drawback element1142may be disposed between a shutoff valve (e.g., shutoff valve1122) and the electrode1102. Similarly, the drawback element1144may be disposed between a shutoff valve (e.g., shutoff valve1124) and the electrode1102. The drawback element1146may be disposed between a shutoff valve (e.g., shutoff valve1126) and the electrode1104. The drawback element1148may be disposed between a shutoff valve (e.g., shutoff valve1128) and electrode1104.

In some embodiments, the drawback elements1142-1148may each comprise a suction force storage element (e.g., a spring-loaded bellows). For example, the drawback elements1142-1148may include a spring1142a-1148adisposed within a chamber (or “housing”), and each drawback element1142-1148may be biased to draw coolant1106from a respective fluid path segment. For example, the drawback element1142may be biased to draw back liquid coolant1106from fluid path segment1112a; the drawback element1144may be biased to draw back liquid coolant1106from fluid path segment1112b; the drawback element1146may be biased to draw back liquid coolant1106from fluid path segment1114a; and the drawback element1148may be biased to draw back liquid coolant1106from fluid path segment1114b.

In some embodiments, the drawback apparatus1140, which may be biased to empty liquid coolant1106from within the apparatus1140to the supply path1150, may generate a suction force (e.g., by movement of a piston) which may be transferred to the drawback elements1142-1148, e.g., via the liquid coolant1106, thereby compressing the springs1142a-1148a. Upon electrode1102and/or1104removal, the springs1142a-1148amay expand, thereby generating a suction which may draw the liquid coolant1106away from a gap formed in the path1112and/or a gap formed in the path1114, and into the chamber of the respective drawback elements1142-1148.

Since the drawback elements1142-1148may be lighter and smaller than the drawback apparatus' described above (e.g.,FIGS.5and7), such a configuration may reduce an overall size and/or weight of the system elements that may be located directly on the welding apparatus relative to those described above (e.g., system500or system700). Also, the master cylinder1140and associated system actuating element may be remotely located from the welding apparatus to further reduce size and/or weight on the welding apparatus

In various embodiments, such as preceding a scheduled maintenance of the system1100, the shutoff valve1120and the shutoff valves1124and1128may activate to block flow of coolant1106from the coolant supply1108and block flow and/or backflow of coolant1106to and/or from the coolant return1110, respectively.

In some embodiments, the drawback apparatus1140and/or drawback elements1142-1148may not activate until the shutoff valve1120,1124and1128have shut off flow of the coolant1106. In some embodiments, the shutoff valves1122and1126may be closed after drawback elements1142-1148have been activated. Once active, the drawback elements1142-1148may draw fluid away from a gap or break in the liquid coolant paths1112,1114by pulling coolant1106into a reservoir (e.g., a chamber within the drawback elements1142-1148).

Once the gap or break is corrected, e.g., upon completion of maintenance, one or more of the shutoff valves1120-1128may be opened to allow flow of coolant1106. In some embodiments, the drawback elements1142-1148may push the coolant1106from their respective reservoirs back into the paths1112and/or1114.

It will be appreciated that although five valves1120-1128, one drawback apparatus1140, and four drawback elements1142-1148are shown here, other embodiments may include a greater or lesser number of such components. For example, fewer valves and/or draw back elements may be used if only one electrode is removed per maintenance cycle (i.e., only one electrode is detached at a given time). By way of a further example, using a master drawback apparatus for each liquid coolant path may allow the system1100to function without the master valve1120.

It will further be appreciated that one or more actuators (e.g., as described herein) may be used to control operation of the drawback apparatus1140, drawback elements1142-1148, and/or valves1120-1128. For example, as described above, one or more actuators may trigger operation of such components in preparation for a scheduled maintenance of the system1100. In some embodiments, such one or more actuators may be remote actuators (e.g., located off of the welding apparatus).

FIG.12is a flowchart illustrating an operation of a liquid cooling system (e.g., system1100) according to some embodiments. It will be appreciated that although the steps1202-1218below are described in a specific order, the steps1202-1218, in some embodiments, may also be performed in a different order. Each of the steps1202-1218, in some embodiments, may also be performed sequentially, or serially, and/or in parallel with one or more of the other steps. In some embodiments, operation of the liquid cooling system may include a greater or lesser number of such steps.

In step1202, a supply valve (e.g., supply valve1120) is opened in a supply path (e.g., supply path1150) to allow a liquid coolant (e.g., liquid coolant1106) to flow through the supply path to a first electrode coolant path (e.g., electrode coolant path1112) to cool a first welding electrode (e.g., electrode1102) and to a second electrode coolant path (e.g., electrode coolant path1114) to cool a second welding electrode (e.g., electrode1104). In some embodiments, the first electrode coolant path has a first supply-side electrode coolant segment (e.g., segment1112a) between the supply path and the first welding electrode, and a first return-side electrode coolant segment (e.g., segment1112b) between the first welding electrode and a return path (e.g., return path1152). Similarly, the second electrode coolant path may have a second supply-side electrode coolant segment (e.g., segment1114a) between the supply path and the second welding electrode, and a second return-side electrode coolant segment (e.g., segment1114b) between the second welding electrode and the return path. A drawback master (e.g., drawback apparatus1140) may be coupled to the supply path between the supply valve and the first electrode coolant path, the drawback master being biased to empty the liquid coolant from the drawback master into the supply path.

In step1204, a first valve (e.g., valve1122) coupled in the first supply-side electrode coolant segment may be opened to allow the liquid coolant to flow from the supply path through the first supply-side electrode coolant segment to the first welding electrode. In some embodiments, the first supply-side electrode coolant segment may have a first drawback slave (e.g., drawback element1142) between the first valve and the first welding electrode. The first drawback slave may be biased to draw the liquid coolant from the first supply-side electrode coolant segment.

In step1206, a second valve (e.g., valve1124) coupled in the first return-side electrode coolant segment may be opened to allow the liquid coolant to flow from the first welding electrode through the first return-side liquid coolant segment to the return path. In some embodiments, the first return-side liquid coolant segment may have a second drawback slave (e.g., drawback element1144) between the first welding electrode and the second valve. The second drawback slave may be biased to draw the liquid coolant from the first return-side liquid coolant segment.

In step1208, a third valve (e.g., valve1126) coupled in the second supply-side liquid coolant segment may be opened to allow the liquid coolant to flow from the supply path through the second supply-side liquid coolant segment to the second welding electrode. In step1210, a fourth valve (e.g., valve11216) may be coupled in the second supply-side liquid coolant segment to allow the liquid coolant to flow from the second welding electrode to the return path.

In step1212, the supply valve may be closed in order to stop or reduce the flow of the liquid coolant through the supply path. Similarly, the second valve may also be closed to stop or reduce the flow or backflow of the liquid coolant through the first return-side liquid coolant segment, and the fourth valve may be closed to stop or reduce the flow or backflow of the liquid coolant through the second return-side liquid coolant segment.

In step1214, after the supply valve, second valve and fourth valve have been closed, the drawback master may exert a suction force sufficient to drawback the liquid coolant from the supply path, thereby transferring the suction force to each of the first drawback slave and the second drawback slave. For example, movement of a piston disposed within the master drawback may exert the suction force. Movement of the piston may be triggered, for example, immediately prior to the planned removal of the first electrode. In some embodiments, the transferred suction force causes the first drawback slave to discharge the liquid coolant therein into first supply-side liquid coolant segment, and the second drawback slave to discharge the liquid coolant therein into the first return-side liquid coolant segment.

In step1216, after the drawback master has exerted the suction force, the first valve may be closed in order to stop or reduce flow of liquid coolant through the first supply-side liquid coolant segment. In some embodiments, a portion of the first supply-side liquid coolant segment between the first valve and the first welding electrode, and a portion of the first return-side liquid coolant segment between the first welding electrode and the second valve may be isolated from the supply path and the return path.

In step1220, after the first valve has been closed, the first welding electrode may be at least partially detached, thereby causing the first drawback slave and the second drawback slave to exert the suction force transferred from the drawback master to draw the liquid coolant away from a gap formed when the first welding electrode is at least partially detached. For example, at least partially detaching the electrode may cause springs (e.g., spring1142a,1144a), compressed by the suction force exerted by the drawback master, disposed within the drawback elements to expand, thereby drawing the liquid coolant away from the gap.

FIG.13is a diagram of a fluid flow system1300for cooling welding electrodes1302,1304including independent fluid shutoff and drawback for individual fluid path segments1312a-dof a single fluid path1312according to some embodiments. In the illustrated embodiment, the valves1320-1326can each be a solenoid or pneumatically actuated valves, a no-return check valve, or otherwise. In some embodiments, coolant1306is provided to fluid path1312via coolant supply1308, and coolant1306is returned from path1312via coolant return1308. In some embodiments, coolant1306is provided to the path1312from the coolant supply1308via a supply line, and that the coolant1306may be returned to the coolant return1308via a return line.

It will be appreciated that the features of system1300may be the same or different from the corresponding features discussed herein (e.g., welding electrodes202,204, shutoff valves220,222, welding electrodes702,704, or the like).

In some embodiments, shutoff valves1320-1326may isolate segments1312a-dfrom the rest of the system1300thereby shutting off fluid flow through the path1312. The shutoff valves1320-1326may be controlled (e.g., electrically) or be mechanical. The shutoff valves1320-1326may be actuated or triggered to shut off fluid flow to and/or from the segments1312a-dwhen the electrodes1302,1304are removed or at least partially detached (e.g., for a scheduled maintenance or in response to a failure).

As mentioned above, system1300provides, in some embodiments, independent fluid1306removal (or “drawback”) for each of the path segments1312a-d. As shown, the drawback apparatus'1340-1346may each be positioned on a segment of the fluid path1312. More specifically, drawback apparatus1340is positioned on segment1312a; drawback apparatus1342is positioned on segment1312b; drawback apparatus1344is positioned on portion1312c; and drawback apparatus1346is positioned on portion1312d.

In the illustrated embodiment, each of the drawback apparatus'1340-1346may have the same configuration and/or operation as the drawback apparatus340discussed above. Thus, for example, each of the drawback apparatus'1340-1346may include a piston disposed within a chamber. In other embodiments, they can each have a different configuration and/or operation, e.g., such as the configuration and/or operation of drawback valve800or1000, discussed herein.

In some embodiments, when one or both electrodes are detached and gaps are formed along path1312, the shutoff valves1320-1326may engage to stop flow of coolant along the segments1312a-d. One or more of the drawback apparatus'1340-1346may drawback fluid from the segments1312a-d. Since the shutoff valves1320-1326do not allow for coolant to be brought to segments1312a-d, the coolant may be drawn away from the gaps, e.g., drawback element1340may draw coolant back from the gap along segment1312aand drawback element1344may draw coolant back from the gap along segment1312b, and so forth.

It will be appreciated that although four shutoff valves1320-1326and four drawback apparatus'1340-1346are shown here, in other embodiments a greater or lesser number of such valves and/or drawback apparatus' may be used. Similarly, such valves and drawback apparatus may positioned elsewhere on the fluid path.

FIG.14Ais a diagram of a fluid flow system1400for cooling welding electrodes1402,1404including a drawback valve apparatus1440and a flow sensor1460according to some embodiments. It will be appreciated that some of the features of system1400may be the same or different from the corresponding features discussed above (e.g., welding electrodes202,204, drawback elements742-748, or the like.). Accordingly, the drawback elements1442-1448may have a same or similar configuration and/or operation as the drawback elements742-748described above. Likewise, the valves1420-1424may also have a same or similar configuration and/or operation as the valves720-724described above, although in other embodiments, the valves1420-1424may be included within the drawback elements1442-1448(e.g., as described in drawback valve800).

InFIG.14A, coolant supply1408provides coolant1406along paths1412and1414to cool welding electrodes1402and1404, respectively. The coolant1406may then be received by coolant return1410(where the coolant1406, in some embodiments, may be recirculated). The system1400may include valves1420and1422that may adjust flow of the coolant1406along the path1412(e.g., if a gap or a break is detected in the path1412, or preceding the planned removal of an electrode1402). Similarly, the system1400may include valves1424and1426that may adjust flow of the coolant1406along the path1414. Drawback elements1442and1444may draw coolant1406into the drawback elements1442and1444, respectively, e.g., if a gap or break is detected in the path712, or preceding a scheduled maintenance. Similarly, drawback elements746and748may draw coolant1406into the drawback elements1446and1448, respectively, if there is a gap or break is detected in the path714, or preceding a scheduled maintenance.

In the example depicted inFIG.14A, both paths1412and1414receive coolant1406from the coolant supply1408along, at least partially, the same path (i.e., supply path1450). Similarly, both paths1412and1414provide coolant1406to the coolant return1410along, at least partially, the same path (i.e., return path1452).

In various embodiments, the drawback element1442may be disposed between a valve (e.g., valve1420) and the electrode1402. Similarly, the drawback element1444may be disposed between a valve (e.g., valve1422) and the electrode1402. The drawback element1446may be disposed between a valve (e.g., valve1424) and the electrode1404. The drawback element1448may be disposed between a valve (e.g., valve1426) and electrode1404.

In some embodiments, the valves1420-1424and drawback elements1442-1448, and components thereof (e.g., piston, or the like) may be operated, or controlled, by a flow controller (or, “flow processor”)1470. Although the flow controller1470is shown here operating four valves1422-1424and drawback elements1442-1444, in other embodiments the flow controller1470may operate a greater or lesser number of such valves and/or drawback elements. It will be appreciated that there may be any number of flow controllers and/or actuators. In some embodiments, the flow controller1470may be remote from the system1400.

In the illustrated embodiment, the system1400may include one or more flow sensors1460. As shown, the flow sensor1460may be positioned in the return path1452, although other embodiments may include one or more other flow sensors, in addition to or instead of the flow sensor1460. For example, other embodiments may include flow sensor(s) in the supply path1450, first electrode path1412, and/or second electrode path1414. In the illustrated embodiment, the flow sensor1460may detect one or more flow rates of the liquid coolant1406flowing through the return path1452(e.g., 12 liters per minute). The flow sensor1460may detect, for example, low flow conditions in the return path1452, which may indicate a malfunction in the system1400, such as an inadequate supply of coolant, blockages in one or more of the paths, malfunctioning valves, lost electrodes, and so forth.

In some embodiments, the flow controller1470may detect malfunctions based on the sensor data (e.g., from sensor1460) and one or more flow conditions. For example, the flow controller1470, or other associated device (e.g., a server or other processor), may compare sensor1460data (e.g., flow rates) to previously collected sensor data in order to detect changes in flow rate, which may indicate a malfunction. Similarly, the flow controller may compare the sensor1460data to a threshold value. For example, if a detected flow rate falls below a predetermined rate, then it may indicate a malfunction. Example flow conditions may include:

Inadequate coolant supply: If a detected flow rate is lower than a predetermined supply threshold rate, then it may indicate an inadequate coolant supply. Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate an inadequate coolant supply.

Blockage in a path (e.g., electrode path, supply path, return path, and so forth): If a detected flow rate is lower than a predetermined blockage threshold rate, then it may indicate that one or more of paths are blocked (or, “clogged”). Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate that one or more of paths are blocked.

Valve and drawback element malfunction: If a detected flow rate is lower than a predetermined valve threshold rate, then it may indicate one or more malfunctioning valves and/or drawback elements. Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate one or more malfunctioning valves.

Lost electrode: If a detected flow rate is lower than a predetermined electrode threshold rate, then it may indicate that one or more welding electrodes have at least partially detached. Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate that one or more welding electrodes have at least partially detached.

In some embodiments, the flow controller1470may trigger one or more action responses based on the sensor data (e.g., detected by sensor1460) and one or more flow conditions. Example action response may include:

Stop coolant flow: Close one or more valves to stop coolant flow through one or more of the paths. For example, the coolant flow may be stopped, or substantially stopped, in the event of a lost electrode.

Drawback liquid coolant: drawback liquid coolant from one or more of the paths with one or more associated drawback elements.

It will be appreciated that although a flow controller may detect malfunctions, in other embodiments another device may perform such functionality (e.g., a server or other processor) in addition to, or instead of, the flow controller1470. In various embodiments, each valve1420,1422,1424, and/or1426may share one or more flow controllers (or may each be associated with a separate flow controller). The flow controller1470may be coupled to any number of sensors (e.g., flow sensors, temperature sensors, discussed below, and so forth), e.g., for detecting and/or responding to malfunctions.

In some embodiments, upon detecting a malfunction, the flow controller1470may control a subset of valves and/or drawback elements. For example, if a malfunction in the path1412is detected (e.g., based on sensor data from sensor1460), the flow controller1470may activate valves1420and/or1422to shut off coolant1406flow. If a malfunction in the path1414is detected (e.g., based on sensor data from sensor1460), the flow controller1470may activate valves1424and1426to shut off coolant1406flow.

FIG.14Bis a diagram of the fluid flow system1400for cooling the welding electrodes1402,1404including the drawback valve apparatus1440, the flow sensor1462and flow sensor1462according to some embodiments.

Similar to flow sensor1460, sensor1462may detect a flow rate of the liquid coolant1406in the supply path1450. The sensor1462, in combination with the sensor1460, may provide more accurate detection of various malfunctions. For example, data from senor1460that may indicate a malfunction may be confirmed by corresponding data from sensor1462.

In some embodiments, the flow controller1470may detect malfunctions based on sensor data from one or both of the flow sensors1460and1462, and one or more flow conditions. Similar to the flow conditions discussed above, example flow conditions in various embodiments may include:

Inadequate coolant supply: If a detected flow rate in both the supply path (e.g., by sensor1462) and the return path (e.g., by sensor1460) is lower than a predetermined threshold rate, then it may indicate an inadequate coolant supply. Similarly, if a flow rate both in the supply path and return path is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements (e.g., by sensors1462and/or1460) and one or more previous flow sensor measurements (e.g., by sensor1462and/or1460), then it may indicate an inadequate coolant supply.

Blockage in a path (e.g., electrode path, supply path, return path, and so forth): If a detected flow rate in both the supply path (e.g., by sensor1462) and the return path (e.g., by sensor1460) is lower a predetermined blockage threshold rate, then it may indicate that one or more of paths are blocked (or, “clogged”). Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate that one or more of the paths are blocked.

Valve and/or drawback element malfunction: If a detected flow rate both in the supply path (e.g., by sensor1462) and the return path (e.g., by sensor1460) is lower than a predetermined valve threshold rate, then it may indicate one or more malfunctioning valves (e.g., valves1420-1424) and/or drawback elements (e.g., drawback elements1442-1448). Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate one or more malfunctioning valves.

Lost electrode: If a detected flow rate in the return path (e.g., by sensor1460) is lower than a detected flow rate in the supply path (e.g., by sensor1462) by more than a predetermined blockage threshold rate, then it may indicate that one or more welding electrodes have at least partially detached. Similarly, if a difference in flow rates is increased by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate that one or more welding electrodes have at least partially detached.

In some embodiments, the flow controller1470may trigger one or more action responses (e.g., as described above) based on the sensor data (e.g., detected by sensor1460) and one or more flow conditions.

FIG.14Cis a diagram of the fluid flow system1400for cooling the welding electrodes1402,1404including the drawback valve apparatus1440, the flow sensors1460,1462, and additional auxiliary equipment1454according to some embodiments.

In some embodiments, a flow rate on a plumbing tap for auxiliary equipment1454(e.g., a transformer) may be calculated based on a difference between flow rates detected by the sensors1460and1462. This may be helpful, for example, to ensure that the auxiliary equipment1454, which can often be expensive, is not damaged due to improper flow within the system1400.

FIG.15is a flowchart illustrating an example operation of a liquid cooling system (e.g., liquid cooling system1400) configured to detect and respond to malfunctions (e.g., at least one partially detached electrode, clogged paths, and so forth) according to some embodiments.

It will be appreciated that although the steps1502-1514below are described in a specific order, the steps1502-1514may also be performed in a different order. Each of the steps1502-1514may also be performed sequentially, or serially, and/or in parallel with one or more of the other steps1502-1514. In some embodiments, detection and/or response to malfunctions may include a greater or lesser number of such steps.

In step1502, a first welding electrode (e.g., welding electrode1402) is cooled by liquid coolant (e.g., coolant1406) flowing from a supply path (e.g., supply path1450) through a first electrode path (e.g., electrode path1412) to a return path (e.g., return path1452). More specifically, a coolant supply (e.g., supply1408) may supply the liquid coolant to the first electrode path via the supply path. Since the first welding electrode is included in the first electrode path, the first electrode is cooled by the flowing liquid coolant.

In step1504, a second welding electrode (e.g., welding electrode1404) is cooled by the liquid coolant flowing from the supply path through a second electrode path (e.g., electrode path1414) to the return path. More specifically, the coolant supply may supply the liquid coolant to the second electrode path via the supply path. Since the second welding electrode is included in the second electrode path, the second electrode is cooled by the flowing liquid coolant.

In step1506, a supply flow rate of the liquid coolant in the supply path may be detected by a first flow sensor (e.g., flow sensor1462). In step1508, a return flow rate of the liquid coolant in the return path may be detected by a second flow sensor (e.g., flow sensor1460).

In step1510, one or more malfunctions (e.g., a clogged electrode path, one or more at least partially detached electrodes, and so forth) may be determined based on the detected return flow rate and the detected supply rate. For example, the flow controller may compare the detected return flow rate and the detected supply flow rate, and if the detected return flow rate is less than the detected supply flow rate, then it may indicate a malfunction. Other flow conditions, e.g., as described above, may be used to determine a malfunction in the system.

In optional step1512, the one or malfunctions may be identified (e.g., by flow controller) based on flow conditions, e.g., as described above. For example, if the detected return flow rate approaches zero positive flow, or a negative flow (i.e., backflow), then the malfunction may be identified as detached, or at least partially detached, welding electrodes.

In step1514, an action response may be triggered (e.g., by the flow controller1470) based on the detected supply flow rate and the detected return flow rate. For example, action responses may include, as described above, opening or closing valves (e.g., valves1420-1420) to stop or reduce liquid coolant flow, drawing back liquid coolant from the electrode paths with one or more drawback elements (e.g., drawback element1442-1448), and so forth.

FIG.16Ais a diagram of a fluid flow system1600for cooling welding electrodes1602,1604including a drawback valve apparatus1640and flow sensors1664,1666according to some embodiments. It will be appreciated that some of the features of system1600may be the same or different from the corresponding features discussed above (e.g., welding electrodes1402,1404, electrode paths1412,1414, or the like.). Accordingly, for example, the drawback elements1642-1648and valves1620-1626may have a same or similar configuration and/or operation as the drawback elements1442-1448and valves1420-1426described above.

In some embodiments, the valves1620-1624may comprise proportional control valves which may adjust a flow rate of the liquid coolant flowing through their respective paths. For example, the valves1620-1464may stop or reduce the flow of liquid coolant by moving the valve towards a closed position, and/or increase the flow of liquid coolant by moving the valve towards an open position. It will be appreciated that, in some embodiments, the valves1620-1624may each independently move between be the closed position, the open position, and partially closed position(s) (or, partly open position(s)), e.g., in response to signaling from one or more flow controllers, actuators, and/or other control device(s).

In the illustrated embodiment, the electrode paths1612,1614include flow sensors1664and1666, respectively. Similar to sensors1460,1462, described above, the sensor1664may detect flow rates of the liquid coolant1606flowing through electrode path1612and the sensor1666may detect flow rates of the liquid coolant1606flowing through the electrode path1614. Individual flow sensors for each electrode path may, for example, allow for more accurate detection and/or identification of malfunctions, and/or provide indication of the relative position of proportional control valves (e.g., valves1620-1624) for feedback to a proportional flow controller(s) (e.g., flow controller1670) to maintain a desired flow rate in each electrode path. For example, a sudden shift in flow rate on only sensor1664may indicate that the welding electrode1602may have detached, or at least partially detached. Similarly, a sudden shift in flow rate on only sensor1666may indicate that the welding electrode1604may have detached, or at least partially detached.

In some embodiments, more specifically, flow controller1670may detect malfunctions based on sensor data from one or both of the flow sensors1664and1666, and one or more flow conditions. Similar to the flow conditions discussed above, example flow conditions in various embodiments may include:

Inadequate coolant supply: If a detected flow rate in both electrode paths (e.g., as detected by sensors1664,1666) are lower than a predetermined supply threshold rate, then it may indicate an inadequate coolant supply. Similarly, if a flow rate in both electrode paths is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate an inadequate coolant supply.

Blockage in a path (e.g., electrode path, supply path, return path, and so forth): If a detected flow rate in an electrode path (e.g., by sensor1664or1666) is lower than a predetermined blockage threshold rate, then it may indicate a blockage in that path. Similarly, if a flow rate in an electrode path is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate a blockage in that path.

Valve and/or drawback element malfunction: If a detected flow rate in an electrode path (e.g., by sensor1664or1666) is lower than a predetermined valve threshold rate, then it may indicate one or more malfunctioning valves (e.g., valves1420-1424) and/or drawback elements (e.g., drawback elements1442-1448) in that path. Similarly, if a flow rate in an electrode path is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate one or more malfunctioning valves and/or drawback elements in that path.

Lost electrode: If a detected flow rate in an electrode path (e.g., detected by sensor1664or1666) is lower than a predetermined electrode threshold rate, then it may indicate that the welding electrode in that path has detached, or at least partially detached. Similarly, if a flow rate is reduced by at least a predetermined amount, e.g., as indicated by one or more current flow sensor measurements and one or more previous flow sensor measurements, then it may indicate that the welding electrode in that path has detached, or at least partially detached.

In some embodiments, the flow controller1670may trigger one or more action responses based on the sensor data (e.g., detected by sensor1666and/or1666) and one or more flow conditions. Example action responses may include:

Stop coolant flow: Close one or more valves to stop coolant flow through one or more of the paths. For example, the coolant flow may be stopped, or substantially stopped, in the event of a lost electrode, or preceding a scheduled maintenance.

(The decision to remove an electrode for maintenance probably won't be in response to data from a single sensor on the return. In the current state of the art it would even be an advanced concept for systems with the capability to measure both flow rate and temperature for individual electrodes.)

Reduce coolant flow: Adjust (e.g., partially close) one or more valves to reduce coolant flow through one or more of the paths.

Increase coolant flow: Adjust (e.g., open or partially open) one or more valves to increase coolant flow through one or more of the paths.

Drawback liquid coolant: drawback liquid coolant from one or more of the paths with one or more associated drawback elements.

In some embodiments, the flow controller1670may control drawback elements (e.g., drawback elements1442-1448). For example, after the valves1620and1622shut off flow of coolant1606, the flow controller may control the drawback elements1642,1644,1646, and/or1648. The flow controller may control a subset of the drawback elements. For example, after detecting a malfunction in the path1612, the flow controller1670may control the drawback elements1642and/or1644to drawback coolant1606from the paths. Upon detection or a command that the malfunction has been corrected (e.g., the welding electrode1602has been replaced), then the flow controller1670may control the drawback elements1642and/or1644to push the coolant back to the paths. Similarly, after detecting a malfunction in the path1614, the flow controller may control the drawback elements1646and/or1648to drawback coolant1606from the paths. Upon detection or a command that the malfunction has been corrected, then the flow controller1670may control the drawback elements1446and/or1448to push the coolant back to the paths.

FIG.16Bis a diagram of the fluid flow system1600for cooling the welding electrodes1602,1604including the drawback valve apparatus1640and flow sensor1662-1666according to some embodiments.

In some embodiments, the supply path1650may include flow sensor1662. The additional sensor1662may provide, for example, more accurate detection and/or identification of system malfunctions. Similar to sensors1664,1666, the flow sensor1662may detect flow rates of the liquid coolant1606in the supply path1650.

In some embodiments, more specifically, the flow controller1670may detect and/or identify malfunctions based on sensor data from some or all of the flow sensors1662-1666, and one or more flow conditions. For example, if the flow rate detected by a sensor in either electrode path decreases in conjunction with an increase in flow rate detected by the sensor in the supply path, then it may indicate a malfunction, e.g., the welding electrode in that path has detached, or least partially detached. Other example flow conditions are described herein.

In some embodiments, the flow controller1670may trigger one or more action responses (e.g., as described above) based on the sensor data and/or one or more flow conditions.

FIG.17is a diagram of a fluid flow system1700for cooling welding electrodes1702,1704including a drawback valve apparatus1740, flow sensors1762-1766, and temperature sensors1780-1784according to some embodiments. It will be appreciated that some of the features of system1700may be the same or different from the corresponding features discussed above (e.g., welding electrodes1402,1404, electrode paths1412,1414, flow sensors1462-1466, or the like.). Accordingly, for example, the flow sensors1762-1766, drawback elements1742-1748and valves1720-1726may have a same or similar configuration and/or operation as the flow sensors1462-1466, drawback elements1442-1448and valves1420-1426described above.

In some embodiments, the supply path1750may include flow sensor1762and temperature sensor1780. Similarly, the electrode paths1712,1714may include flow sensors1764,1766, respectively, and temperature sensors1782,1784, respectively. Although three flow sensors and three temperature sensors are shown here, it will be appreciated that this is for illustrative purposes only, and other embodiments may have a greater or lesser number of such flow and/or temperature sensors.

In some embodiments, the temperature sensors1780-1784may detect a temperature of the liquid coolant1706flowing through their respective path. This may help, for example, to maintain a predetermined temperature of the liquid coolant1706, e.g., an optimal differential temperature for coolant entering and exiting the electrodes1702,1704, and/or preventing damage to system1700components by detection differential temperatures above a predetermined threshold. In various embodiments, by combining the flow sensors17621766with the temperature sensors1780-1784, the flow controller1770may be able to determine a thermal transfer rate based on the detected temperature(s) and flow rate(s), which may, for example, help predict system failures (e.g., an electrode failure) or optimize welding conditions, i.e., adjusting welding electrode current and/or cycle time.

In various embodiments, the flow controller1770may trigger one or more action responses based on the measured temperature and/or flow sensor data, and one or more flow conditions. Example flow conditions may include:

Thermal transfer rate: If the thermal transfer rate exceeds a thermal transfer threshold value, then it may indicate either an existing malfunction in the system, or a predicted malfunction (e.g., a welding electrode failure because the welding electrode may be operating at excessive temperatures). Similarly, if a thermal transfer rate changes (e.g., increased) by at least a predetermined amount, e.g., as indicated by one or more current thermal transfer rates and one or more previous thermal transfer rates, then it may indicate either an existing malfunction in the system, or a predicted malfunction.

Liquid Coolant Temperature: If a detected temperature (e.g., an absolute temperature or a differential temperature) of liquid coolant flowing through a path exceeds a threshold temperature, then it may indicate an existing malfunction, or a predicted malfunction. Similarly, if a detected temperature increases or decreases by at least a predetermined amount, e.g., as indicated by one or more current temperatures and one or more previous temperatures, then it may indicate either an existing malfunction in the system, or a predicted malfunction.

In some embodiments, the flow controller1770may trigger an action response based on the detected sensor data and/or flow condition(s). Example action responses may include adjusting the temperature to a predetermined threshold, e.g., by lowering a temperature at the supply1708, adjusting valves1720-1724to affect flow rate(s) of the liquid coolant1706, and so forth. Additional action responses are described above (e.g., drawing back liquid coolant).

FIG.18is a flowchart illustrating an example operation of a liquid cooling system (e.g., liquid cooling system1700) including flow sensors (e.g., flow sensors1762-1766) and temperature sensors (e.g., temperature sensor1780-1784) according to some embodiments.

It will be appreciated that although the steps1802-1812below are described in a specific order, the steps1802-1812may also be performed in a different order. Each of the steps1802-1812may also be performed sequentially, or serially, and/or in parallel with one or more of the other steps1802-1812. In some embodiments, a greater or lesser number of such steps may be included.

In step1802, a first welding electrode (e.g., welding electrode1702) is cooled by liquid coolant (e.g., coolant1706) flowing from a supply path (e.g., supply path1750) through a first electrode path (e.g., electrode path1712) to a return path (e.g., return path1752). More specifically, a coolant supply (e.g., supply1708) may supply the liquid coolant to the first electrode path via the supply path. Since the first welding electrode is included in the first electrode path, the first electrode is cooled by the flowing liquid coolant.

In step1804, a second welding electrode (e.g., welding electrode1704) is cooled by the liquid coolant flowing from the supply path through a second electrode path (e.g., electrode path1714) to the return path. More specifically, the coolant supply may supply the liquid coolant to the second electrode path via the supply path. Since the second welding electrode is included in the second electrode path, the second electrode is cooled by the flowing liquid coolant.

In step1806, a first flow rate of the liquid coolant in the supply path may be detected by a first flow sensor (e.g., flow sensor1762). Similarly, a second flow rate of the liquid coolant in the first electrode path may be detected by a second flow sensor (e.g., flow sensor1764), and a third flow rate of the liquid coolant in the second electrode path may be detected by a third flow sensor (e.g., flow sensor1766).

In step1808, a first temperature of the liquid coolant in the supply path may be detected by a first temperature sensor (e.g., flow sensor1780). Similarly, a second temperature of the liquid coolant in the first electrode path may be detected by a second temperature sensor (e.g., temperature1782), and a third temperature of the liquid coolant in the second electrode path may be detected by a third temperature sensor (e.g., temperature sensor1784).

In step810, one or more potential malfunctions may be determined (e.g., by flow controller1770) based on some or all of the detected temperature and/or detected flow rates. For example, the flow controller may calculate a thermal transfer rate based on the detected temperatures and flow rates. The flow controller may then compare the thermal transfer rate to a threshold transfer rate, and if it exceeds the threshold, then the flow controller may predict a malfunction (e.g., an electrode failure). Similarly, the flow controller may compare a current thermal transfer rate with a previous thermal transfer rate, and if the difference exceeds a predetermined amount, the flow controller may predict a malfunction.

In step1812, one or more action responses may be triggered (e.g., by the flow controller) based on the detected sensor data and/or potential malfunctions. For example, the flow controller may close one or more valves (e.g., valves1720-1726) in order to stop flow of coolant through the electrode paths, and/or drawback liquid coolant from the electrode paths (e.g., via drawback elements1742-1748).

It will be appreciated that an example number of flow sensors and temperature sensors are shown and described herein, and other embodiments may include a greater or lesser number of such sensors. For example, one or more flow sensors and/or temperature sensors may be included on each of the supply path, return path, first electrode path and/or second electrode path.

It will further be appreciated, as discussed in the embodiments above, that the electrodes discussed herein may be at least partially detach for a variety reasons. For example, one or more electrodes may be detached in preparation for a scheduled maintenance, or in response to a failure of one or more electrodes.

The present invention(s) are described above with reference to example embodiments. It will be apparent to those skilled in the art that various modifications may be made and other embodiments can be used without departing from the broader scope of the present invention(s). Therefore, these and other variations upon the example embodiments are intended to be covered by the present invention(s).