CA1090428A - Remote control portable wirefeed arc welding system - Google Patents

Remote control portable wirefeed arc welding system

Info

Publication number
CA1090428A
CA1090428A CA296,565A CA296565A CA1090428A CA 1090428 A CA1090428 A CA 1090428A CA 296565 A CA296565 A CA 296565A CA 1090428 A CA1090428 A CA 1090428A
Authority
CA
Canada
Prior art keywords
contactor
relay
gun
wirefeed
delay relay
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA296,565A
Other languages
French (fr)
Inventor
John L. Matasovic (Deceased)
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MATASOVIC STELLA B
Original Assignee
MATASOVIC STELLA B
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MATASOVIC STELLA B filed Critical MATASOVIC STELLA B
Priority to CA296,565A priority Critical patent/CA1090428A/en
Application granted granted Critical
Publication of CA1090428A publication Critical patent/CA1090428A/en
Expired legal-status Critical Current

Links

Abstract

Abstract of the Disclosure A remote control unit for closing a normally open contactor in response to closing of a normally open gun switch in a portable wirefeed arc welding system having a power source including the contactor, a portable wirefeed unit, a welding gun, a ground cable interconnecting the power source and the work, an electrode power cable intercon-necting the power source and the wirefeed unit and gun, and control leads interconnecting the wirefeed unit with the work and the gun; wherein a capacitor in the control unit is operable to place an overide current on the ground and electrode power cables in response to closing of the gun switch, and sensing means comprising a control sensor employing the Hall effect and a sense relay are operable in response to such override current to effect closing of a normally open cycle hold delay relay and the contactor, and a cycle hold delay relay that, in turn, closes a fourth or rearming delay relay which opens the circuit to the sense relay. So long as welding current is drawn, the first control relay remains closed to hold the cycle hold delay relay closed.
An interruption of welding current for two seconds causes the cycle hold delay relay to time out to open the rearming delay relay and the contactor.

Description

Z~

This invention relates to arc welding generally, and more particularly to a portable wirefeed arc welding system.
Conventional portable arc welding systems include a welding machine or power source (preferably a DoCo constant voltage type), a portable wire feeding unit with controls, and a welding gun or torch, with electrode power cables rom the power source to the wire feeding and control unit and to the gun, a ground ca~le between the power source and the work, ,, .
and contactor control and llO or 115 volt AoCo supply cables between the power source and the portable control unlt. The ~:
latter cables are hazardous and their maintenance is an : :~
important factor in efficiency, productivity and costs, especially in welding on bridges, ships, tan~s, pipe lines, or other large structuresO Consequently, elimina~ion of t.hose contactor control and 115 volt AoCo supply cables is very : desirable. :~
That has been accomplished with the so-called arc :-voltage system by using a DoC, motor for the wirefeeder which : 20 operates from the low voltage in the welding current cable, but that requires the main contactor to be closed at all times which maintains the welding cables and welding wire "hot"O
That is a very dangerouæ condition, and an accidental touching -~
of the wire or gun t p to the work sr surrounding grounded structure will cause instantaneous arcing and probable serious 4;~

damage to the wirefeed system, such as a "burnback" o the wire into the gun tip, and possible burning of the operator's eyes if his protective helmet is not in place. Further, arcing on critical weldments not only leaves a cosmetic blemish, but also is metallurgically undesirable.
According, the invention provides in a portable wirefeed arc welding system for depositing metal on a selected piece of work and having a power source including a normally open contactor, a portable wirefeed unit, a welding gun in-cluding a normally open gun switch, a ground cable inter-connecting said power source and said work, an electrode power cable interconnecting said contactor with said wirefeed unit and said gun, and control,leads interconnecting said wirefeed --~
unit with said work and said gun: a remote control unit in-cluding a normally inoperative sensing means, a capacitor connected in series with said gun switch across said power cables and said gun switch and capacitor in serles being ~ ;~
connected in parallel with said sensing`means, a voltage ,~
source, means for charging ~said capacitor from said voltage source in response to closing of the switch to render said sensing means operative to close said contactor for energizing said cables from said power source, and means responsive to closure of the contactor to disconnect the capacitor and sense relay from the power cables.
This invention eliminates the conventional ~ ~ .
contactor control and 115 volt A.C. supply cables between the portable wirefeed and thé power source of an arc welding ~- system without requiring the welding cables and wire to be ~; "hot" at all times. This is accomplished by providing a control unit at the power source including a capacitor operable in response to closing of the gun switch to place
2-an override current on the welding cables, and sensing means operable in response to such override current to effect closing of the power source contactor to supply welding current to the electrode and ground welding cables.
In the preferred embodiment of the invention, that sensing means comprises a control sensor employing the Hall effect, and a sense relay which is operable in response to a predetermined override current on the welding cables to close a normally open cycle hold delay relay and the power source contactor to supply wPlding current to the gun.
Closing of the cycle hold delay relay, in turn, closes a rearming delay relay which opens the circuit to the sense relay. If the cycle hold delay relay times out after a predetermined time, preferably two seconds, the circuit to the rearming delay relay is opened and the welding c~ntactor is opened~ Until the rearming delay relay thereafter times out (one-half second), the welding cable capacitor cannot re-energize the system which gives an~ other capacitors tim~ to discharge before rearming the sense relay.
~hen the power source contactor is closed in response to closing of the gun switch, as above described, and welding current is being drawn, the control sensor effects closing of a control relay which remains closed and holds the cycle hold delay relay closed as long as welding current is drawn. Brief interruptions in the welding, preferably of up to two seconds, can occur, however, with-out the contactor being opened. But if the welding current : . ~ . . .: .

-is lost for more than two seconds, a rearming sequence must be followedO This provides an inherent and very desirable burnback controlO
This control system thus eliminates the use of the conventional contactor control and A~Co supply cables between the power source or welding machine and the portable wirefeed control unit in an arc welding system, while the contactor normally is open, by applying a control current override to the welding electrodes and ground cables, in response to initial closing of the gun switch, which is sensed remotely at the welding machine to close the contactor.
~he gun switch therefore serves the two functi~ns of initially causing closing of the normally open welding contactor and, thereafter, controlling the start-stop wirefeeder motor after welding voltage has been established.
In the drawings: ~
FIGURE 1 is a schematic view of a portable wirefeed ~ .
arc welding system embodying this invention; and FIG. 2 is a wiring diagram of the preferred remote control unit employed therein.
The schematic drawing of FIG. 1 illustrates an arc welding system having a conventional power source P;
preferably a DoC~ constant voltage type, with a normally open contactor C controlling the usual welding cables comprising a ground cable G from the power source to the wor~ ~ and an electrode power cable E from the power source ... .. . .

0~
to a portable wirefeeder F which includes a wire speed control S, a wire drive motor D and a supply of weld wire :-on reel R. The weld wire extends with the power cable E
through a suitable conduit from the wirefeeder to the welding gun A. The gun switch T is connected in the usual manner with the wire speed control S by a lead U, and a lead V inter-connects the control S and the work ~O The use of a shielding gas is optional and is illustrated in FIG. 1 as passing ~;
through the wirefeeder under the control of a solenoid valve therein in well known manner. ::
From the preceding it will be noted that the contactor control and 115 volt AoC~ supply cables extending between the portablewirefeeder and the power source in the conventional arc welding system are not employed in the :~
present system. Instead, the system of this invention pro- :
vides a remote control unit, indicated generally by X, which is located at the welding machine or power source P to effect closing of the normally open power source contactor C to : :
supply welding current to the gun A~
~ FIG. 2 comprises a wiring diagram of a preferred ~;
; 20 embodiment of that control unit X which includes two ~:
: transformers Tl and T2 connected across 115 volt AoC~ supply lines Ll and L2. A sense relay Rl is connected across the secondary of transformer Tl with diodes H and J and a 150 ohm resistor K, as illustrated, so that a one-half wave pulsating D~Co voltage is placed across relay Rl, but such voltage is -~
not of sufficient magnitude to close that sense relayO The - ~ , . , relay Rl also i9 connected to the welding cable E through a 10 ohm resistor M and normally closed sampling contacts R4.
The normally open gun switch T is connected to a 1500 MFD
capacitor Cl across the welding cables E, G through normally closed contacts CR2 of a relay CR2. Consequently, when the gun switch T is closed, the 1500 MFD capacitor Cl is placed across the welding ca~les and the voltage across the sense relay Rl increases sufficiently to close the c~ntacts Rl of that relayO
A full-wave bridge rectifier N is connected across the secondary of transformer Tl and at its positive terminal to a line 01 and at its negative terminal to a line 02. The normally open contacts Rl of the sense relay Rl are connected with a cycle hold delay relay R2 across the lines 01 and 02, ~-as are the normally open contacts R2 of the cycle hold delay : relay and a rearming delay relay R4. The normally open `
contacts R3 of a weld current override relay R3 are connected in parallel with the sense relay contacts Rl; and a 3000 MFD
capacitor C2 and a 1000 MFD capacitor C3 are connected in parallel, respectively, with the cycle hold delay relay R2, and the rearming delay relay R40 ; Therefore, when the contacts Rl of the sense relay Rl are closed in response to closing of gun switch T as previous-;: ly described, the cycle hold delay relay R2 is actuated to close its contacts R2, which also are in a welder control circuit WC, to effect closing ofthe contactor C. Such .~ .. , . ~ . . . .
... . .
3~
operation of the cycle hold delay relay R2 also actuates rearming delay relay R4 to open its normally closed contacts R4 and the circuit to sense relay Rl. When cycle hold delay relay R2 times out, preferably in two seconds, the contactor C is opened and the circuit to rearming delay relay R4 is opened to start its timing out. When relay R4 times out, preferably in one-half second, the capacitor Cl is re-energized and the control circuit is back to normal, the delay occasioned by relay R4 enables any capacitors in the welding machine to discharge before the sense relay Rl can be rearmed. ;
A brief sequence of ~he above-described operation is as follows:
1. Gun switch T closing places capacitor Cl across ~ ;
welding cables E, G to provide override current to close sense relay Rl. ~;
2. Closing of Rl closes cycle hold delay relay R2 which~
A. Closes main contactor C.
B. Closes rearming delay relay R4 which opens circuit to sense relay Rl.
3. Opening of Rl contacts starts cycle hold delay ; relay R2 timing out.
4~ If R2 time8 out:
A. Contactor C is opened. `
B. The circuit to rearming delay relay R4 is i~
opened to start R4 timing out. -..

. .

1~39~

A second portion of the sensing means of the remote control unit X at the welding machine or power source P is a current sensor Sl for sensing the current passing through the welding or electric power cable E. In the preferred embodiment, Sl is a Hall effect sensor which is illustrated .
in FIG. 1 as surrounding the welding cable E. As shown in FIG. 2 sensor Sl is connected across the secondary of trans-former T2 and its output is connected to a conventional operational amplifier OA. A normally non-conductive 2N2905 transistor indicated generally by reference character NT
has its emitter lead EL connected to the positive line 01, its base lead BL to the amplifier OA, and its collector lead CL to one side of a relay R3, the other side of which is connected to the negative line 02, in turn connected to the amplifier OA.
Any time a welding current of 50 amperes or more is drawn through the power cable E and, therefore, through ~ the Hall effect sensor Sl, sufficient voltage is available :~ on the output o the operational amplifier OA to make trans-;~ 20 istor~NT conductive which cIoses relay R3. The contacts R3 of the latter are connected in series with the cycle hold delay relay R2 between line 01 and 02, so that their cIo~ing by such closing of reIay R3 holds relay R2 to prevent its timing out. Brief welding interruptions or extinguishments of the arc for periods of up to two seconds will not result in opening of the contactor C~ However~ if welding current . . .

is lost for two or more seconds, the contactor C will open and the rearming sequence previously set forth herein will follow closing of gun switch T.
As soon as welding voltage is applied to power cable E, relay CR2 is energized to open its normally closed contacts CR2. This transfers control of the gun switch rom the capacitor Cl to the usual wirefeeder start-stop circuit through the gun control lead U tFIGo 1), and allows the ~-gun control switch to serve two functions:
A. Initially effect closing of the normally open .
main contactor.
B. Start-stop wirefeeder motor after welding voltage has been established.

"~ "-: ~ '`''. '' ,~ ' ' ~' " `' ,'- ' .~' ' ''' ~; ~ '' ':

^, -''` '''~' .
' _9_ :, ' . ' : ' ,. : '. ... '

Claims (5)

The embodiments of the invention in which an exclu-sive property or privilege is claimed are defined as follows:
1. In a portable wirefeed arc welding system for depositing metal on a selected piece of work and having a power source including a normally open contactor, a portable wirefeed unit, a welding gun including a normally open gun switch, a ground cable interconnecting said power source and said work, an electrode power cable interconnecting said contactor with said wirefeed unit and said gun, and control leads interconnecting said wirefeed unit with said work and said gun; a remote control unit including a normally inoperative sensing means, a capacitor connected in series with said gun switch across said power cables and said gun switch and capacitor in series being connected in parallel with said sensing means, a voltage source, means for charging said capacitor from said voltage source in response to closing of the switch to render said sensing means operative to close said contactor for energizing said cables from said power source, and means responsive to closure of the contactor to disconnect the capacitor and sense relay from the power cables.
2. In the system according to claim, 1, wherein said sensing means includes a sense relay, and wherein said control unit further comprises a normally open cycle hold delay relay closed by operation of said sense relay to close said contactor.
3. In a system according to claim 2, a normally open rearming delay relay closed by said cycle hold delay relay, closure of said rearming delay relay serving to de-actuate said sense relay.
4. In a system according to claim 3, and a current sensor operable in response to welding current to close said cycle hold delay relay, and a time delay capacitor connected in parallel with the latter; whereby interruption of welding current for a predetermined time period serves to open said cycle hold delay relay and said contactor.
5. In a system according to claim 1, in which said voltage source includes an A.C. source, a rectifier in series with said sensing means across the A.C. source and being operable to provide on said cables a rectified voltage of value insufficient to actuate said sensing means, said capacitor being operable to increase the average value of said rectified voltage, said sensing means being operable in response to said increase in voltage to effect closing of said contactor.
CA296,565A 1978-02-09 1978-02-09 Remote control portable wirefeed arc welding system Expired CA1090428A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA296,565A CA1090428A (en) 1978-02-09 1978-02-09 Remote control portable wirefeed arc welding system

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA296,565A CA1090428A (en) 1978-02-09 1978-02-09 Remote control portable wirefeed arc welding system

Publications (1)

Publication Number Publication Date
CA1090428A true CA1090428A (en) 1980-11-25

Family

ID=4110731

Family Applications (1)

Application Number Title Priority Date Filing Date
CA296,565A Expired CA1090428A (en) 1978-02-09 1978-02-09 Remote control portable wirefeed arc welding system

Country Status (1)

Country Link
CA (1) CA1090428A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008033772A1 (en) * 2006-09-11 2008-03-20 Hypertherm, Inc. Wearable autonomous material processing system
US8350182B2 (en) 2006-09-11 2013-01-08 Hypertherm, Inc. Portable autonomous material processing system
US9522438B2 (en) 2012-11-09 2016-12-20 Hypertherm, Inc. Battery-controlled plasma arc torch system
US9550251B2 (en) 2014-03-28 2017-01-24 Hypertherm, Inc. Power supply assembly for a plasma arc torch system
US10736204B2 (en) 2016-10-21 2020-08-04 Hypertherm, Inc. Plasma power tool

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008033772A1 (en) * 2006-09-11 2008-03-20 Hypertherm, Inc. Wearable autonomous material processing system
US7615719B2 (en) 2006-09-11 2009-11-10 Hypertherm, Inc. Autonomous plasma cutting system
US8203096B2 (en) 2006-09-11 2012-06-19 Hypertherm, Inc. Wearable autonomous material processing system
US8350182B2 (en) 2006-09-11 2013-01-08 Hypertherm, Inc. Portable autonomous material processing system
US8890021B2 (en) 2006-09-11 2014-11-18 Hypertherm, Inc. Portable autonomous material processing system
US9522438B2 (en) 2012-11-09 2016-12-20 Hypertherm, Inc. Battery-controlled plasma arc torch system
US9550251B2 (en) 2014-03-28 2017-01-24 Hypertherm, Inc. Power supply assembly for a plasma arc torch system
US10736204B2 (en) 2016-10-21 2020-08-04 Hypertherm, Inc. Plasma power tool

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