Abstract:
Various welding systems that provide communication over auxiliary (50) or weld power lines (42, 36) are provided. The disclosed embodiments may include a multi-process welding power supply (10) that is communicatively coupled to a pendant (48) via an auxiliary conduit (50) that facilitates the exchange of data and power between components of the welding system (10). In some embodiments, the pendant (48) may also include auxiliary outlets (64, 62) that allow an operator to power auxiliary devices (58, 60) at the weld location. The disclosed embodiments further include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Embodiments are provided that also allow for bidirectional data communication over a power line in networked welding systems.
Abstract:
An external control module (14) is provided for interfacing a welding power supply (12) with a wire feeder (16). The welding power supply (12) is designed to exchange control signals, feedback signals, and so forth over a control cable (30) when coupled to a standard wire feeder. However, the external control module (14) allows the power supply (12) to be used with a wire feeder (16) that is designed to exchange data combined in a single cable (32) with welding power. The module (14) is coupled to welding and workpiece cables (26, 28) from the power supply (12), and to a control cable (30), such as from a multipin connector on the power supply. The module (14) is further coupled to the wire feeder (16) via a welding cable (32). The module combines data with welding power for transmission to the wire feeder, and extracts data from welding power for application to the power supply.
Abstract:
A welding wire feeder (14) includes a magnetic rotational sensor system (56) configured to measure a parameter indicative of a wire feed speed of the welding wire feeder. The magnetic rotational sensor system includes a dipole magnet (110) coupled to a gear (52) driven by an electric motor (42) of the welding wire feeder and a magnetic sensor (108) disposed adjacent to the dipole magnet and configured to measure an angular position of the dipole magnet. The magnetic rotational sensor system also includes a processor (64) configured to receive signals of the angular position measured by the magnetic sensor and to calculate a wire feed speed of the welding wire feeder based upon the angular position signals and configuration parameters of the welding wire feeder.
Abstract:
A method of operating a welding wire feeder includes receiving an input power from a welding power source, actuating a power relay to close and open a first current carrying path for application of the input power, and actuating bypass circuitry coupled in parallel to the power relay to close and open a second current carrying path in coordination with actuating the power relay. The method of operating the welding wire feeder also includes providing a welding wire to a welding torch.
Abstract:
Provided herein are systems including a wire spool having a core with a core diameter and wire wound around the core and having a wire diameter. An outer diameter of the wire spool is defined by a sum of the core diameter and the wire diameter. The systems may also include a sensing system having a sensor component disposed on the wire spool and/or a wire spool hub. The sensing system is adapted to acquire data corresponding to a parameter indicative of the outer diameter of the wire spool.