CN112107418A

CN112107418A - Arc time recording system for automatic dimming welding cap

Info

Publication number: CN112107418A
Application number: CN202010318029.XA
Authority: CN
Inventors: 保罗·H·伦普克; 理查德·D·史密斯; B·J·钱特里
Original assignee: Lincoln Global Inc
Current assignee: Lincoln Global Inc
Priority date: 2019-06-19
Filing date: 2020-04-21
Publication date: 2020-12-22
Anticipated expiration: 2040-04-21
Also published as: CN112107418B

Abstract

A welding helmet is provided that can record the time of welding based on the intensity of the arc detected by a sensor mounted on the helmet. The configured level is compared to the arc intensity detected by the sensor to determine the weld duration. The individual weld times from multiple weld instances may be accumulated over a period of time to provide the operator with a total weld time. The total weld time may be stored in the weld cap.

Description

Arc time recording system for automatic dimming welding cap

Cross Reference to Related Applications

This application claims priority to 16/736,916, U.S. non-provisional patent application No. 1, 8, 2020, which is incorporated herein by reference in its entirety. This application also claims priority from us provisional patent application 62/863,573 filed 2019, 6, 19, which is hereby incorporated by reference in its entirety. This application also claims priority from us provisional patent application 62/930,630 filed 2019, 11, 5, incorporated herein by reference in its entirety.

Technical Field

The present invention relates generally to caps for arc welding, and in particular to techniques for recording arc time in welding caps.

Background

Operators often use visual protection during welding operations, such as using goggles or welding hats. For example, the welding caps may include a dimmer panel or lens that reduces exposure to light from the arc. The lens may be continuously dimmed such that the welding cap is configured to flip up to allow normal viewing by an operator and to flip down to protect the operator during welding. Alternatively, the lens may comprise an auto-darkening filter; the auto-darkening filter is capable of transitioning between a less-blocking state (e.g., substantially transparent) and a more-blocking state (e.g., darkened) similar to a standard welding helmet lens.

Disclosure of Invention

The following summary presents a simplified summary in order to provide a basic understanding of some aspects of the devices, systems, and/or methods discussed herein. This summary is not an extensive overview of the devices, systems, and/or methods discussed herein. It is not intended to identify key or critical elements or to delineate the scope of such devices, systems, and/or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

According to one aspect, a weld cap is provided that includes an analog optical sensor configured to detect incident light and output a signal indicative of a light intensity level. The cap further includes control circuitry configured to receive the signal from the analog optical sensor and to record a weld time based on the signal from the analog optical sensor and the configured light level. The weld time corresponds to the duration of the light intensity level indicated by the analog optical sensor that exceeds the configured light level.

These and other aspects of the present invention will be apparent when viewed in light of the attached drawings, detailed description, and appended claims.

Drawings

The invention may take physical form in certain parts and arrangement of parts, at least one embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

FIG. 1 illustrates an exemplary, non-limiting embodiment of a weld cap in accordance with one or more aspects;

FIG. 2 illustrates an exemplary, non-limiting embodiment of a panel for welding a cap in accordance with various aspects;

FIG. 3 illustrates a block diagram of components of a welding cap, according to an exemplary non-limiting embodiment;

FIG. 4 is a flow diagram of an exemplary, non-limiting embodiment of a control method according to one or more aspects; and

FIG. 5 is a block diagram of an exemplary, non-limiting embodiment of a welding system.

Detailed Description

Embodiments of the present invention relate to systems and methods for tracking arc time using a welding cap. Advanced or sophisticated welding power sources may include features for tracking and maintaining efficiency indicators for operators performing welding operations. While such metrics are useful, advanced welding power supplies may be prohibitively expensive for certain environments. As described herein, a low cost alternative to the features of advanced welding power supplies is to equip the welding caps with an efficiency tracking function. In one example, one such indicator may track how long an operator spends looking at an active welding arc during a predetermined period of time (e.g., a day or a work shift). According to this example, the weld cap may include an optical sensor capable of detecting the intensity of light incident on the sensor. A configurable (e.g., user-selectable) threshold determines the light intensity based on which a counter is run to record the weld time. The counter may accumulate individual weld times from individual weld instances. The accumulated weld time may be stored in the weld cap for later retrieval or reporting. Thus, over a given time frame (e.g., one day), the welding caps track the total amount of time spent welding.

As utilized herein, a "welding system" refers to a device or collection of devices having an appliance adapted for performing a welding operation. Welding operations may include, but are not limited to: welding, brazing, soldering, coating, case hardening, and/or cutting. The appliance may include a laser, a water jet, a welding torch that generates a flame or an arc, and/or any other system for performing a welding operation. According to certain embodiments, the terms "welding" or "welding (weld)" (including other forms of these terms) and in particular arc welding, refer to the deposition of molten metallic material by operating an electric arc. Suitable welding processes include, but are not limited to, submerged arc welding, MIG welding, MAG welding, TIG welding, stick welding, FCAW, and the like.

Various embodiments will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the embodiments. It may be evident, however, that the features described herein may be practiced without these specific details. Moreover, other embodiments are possible, and the features described herein can be practiced and carried out in other than the described manner. The terms and phrases used herein are used for the purpose of promoting an understanding of the present invention and should not be taken to be limiting.

FIG. 1 illustrates a welding helmet 100 having a panel 102 operable to record at least one efficiency indicator of an operator (user) performing a welding operation. In one embodiment, panel 102 may be an auto-darkening panel as described herein. It should be understood that the index recording described herein may be performed with a panel having a standard lens (e.g., a lens with constant shading).

Turning to fig. 2, a detailed view of the faceplate 102 is depicted. The faceplate 102 contains lenses 104 through which an operator may view. The lens 104 may be a standard shutter lens or an auto-darkening lens. The auto-darkening lens may be an LCD shutter that is switchable between a transparent state and a darkened state by the application of a voltage or current. To control the auto-darkening lens 104, the faceplate 102 may include one or more digital optical sensors 106. The digital sensor 106 detects a triggering condition indicative of an arc, such as a light intensity greater than a predetermined threshold or a change in light intensity that exceeds a threshold rate. When a trigger condition is detected, the digital sensor 106 transmits a signal to the control circuit to transition the lens 104 to a darkened state.

The faceplate 102 may also include an analog optical sensor 108. The analog optical sensor 108 detects light incident on the sensor and outputs a signal indicative of the intensity level. As described in more detail below, the control circuitry uses the signal from the analog optical sensor 108 to determine when to start and stop a counter 119 (see fig. 3) that measures the weld time. For example, a configurable intensity level may be set that triggers the counter 119. When the sensed intensity exceeds a configured level, a counter 119 is started. When the intensity subsequently drops below the configured level, the counter 119 stops.

The faceplate 102 may also include a user interface 110. The user interface 110 is located on the back (operator side) of the faceplate 102. The user interface 110 may include input devices, such as buttons, switches, dials, etc., to enable an operator to manually adjust the settings of the cap 100. The user interface 110 may also include a display to output set points or measured weld times.

A control circuit 112 is provided to: control of the counter 119 based on an analog optical sensor, control of the lens 104 based on a digital sensor 106, adjustment of settings or execution of commands entered via the user interface 110, and/or output of information to an operator via a display. According to various embodiments, counter 119 may be a component of the control circuit or may be a separate component. The panel 102 may also include rechargeable solar cells 114 to provide power to: control circuitry 112, user interface 110, analog optical sensor 108, digital sensor 106, and/or lens 104.

Turning to FIG. 3, a block diagram of the components of the weld cap is shown. The components shown in fig. 3 may be included in the cap 100 and/or the panel 102 described above. The control circuitry 118 may receive input from the user interface 116, the digital optical sensor 106, and the analog optical sensor 108. The input from the user interface 116 may include, for example, a reset signal for resetting a stored value (e.g., weld time) or set point, or an adjustment signal for changing a configurable threshold. The digital sensor 106 may provide a switching or triggering signal to the control circuitry 118 to determine the status of the auto-darkening lens (not shown). The analog sensor 108 outputs an intensity signal to the control circuit 118 that is indicative of the light intensity level received by the sensor 108.

The control circuitry 118 may be in communication with a storage device 120, which may be a computer readable storage medium configured to store measurements such as recorded weld times or settings such as configured (e.g., user selectable) light intensity. Further, the control circuitry 118 may output information to a display 122 or transmit information to the welding power source or a computing device via a transceiver 124. According to certain embodiments, the weld cap of fig. 3 may include a magnetic field sensor 107, which may output an intensity signal to the control circuitry 118, as discussed subsequently herein, instead of or in addition to the analog optical sensor 108. Further, as discussed subsequently herein, according to certain embodiments, the welding cap of fig. 3 may include a high-resolution camera 109 instead of or in addition to the analog optical sensor 108 and/or the magnetic field sensor 107.

Turning to fig. 4, a flow chart of a control method is depicted. The control method of fig. 4 may be performed by control circuitry 118 installed in a welding cap, such as cap 100 having faceplate 102 described above. The method may begin at reference numeral 200 where it is determined whether a trigger signal is acquired from a digital optical sensor. As described above, the trigger signal will change the state of the auto-darkening lens to a light-blocking state. As shown in fig. 4, the method may loop until a trigger signal is acquired. When the trigger signal is acquired, the light intensity level acquired from the analog optical sensor is compared to the configured intensity level at 202. If the level reported by the analog optical sensor exceeds the configured level, the start time is captured at 204. If the level does not exceed the configured level, the method returns to the initial loop as shown.

As shown at reference numeral 206, a secondary loop is performed in which the control circuitry checks the light intensity level reported by the analog optical sensor against the configured level in order to detect when the reported level falls below the configured level. When the reported intensity level falls below the configured level, the stop time is captured at 208. At reference numeral 210, the captured stop time is subtracted from the captured start time to obtain the arc time or weld time. This value indicates how long the operator has welded during a particular welding instance or arc instance (e.g., the period of time that the light intensity remains above the configured level). At 212, the calculated arc time is added to a total weld time value that accumulates weld time from all weld instances in a particular time period (e.g., one day). At 214, the start and stop times are reset (e.g., reset to zero) in preparation for the weld time at which the next weld instance was recorded. At 216, it is determined whether to reset the total weld time. For example, a reset signal may be received. If the value should be reset, then the total weld time is reset at reference numeral 218. If the values should not be reset, the method jumps to reference numeral 220 where it is determined whether the configuration level should be adjusted. For example, an operator may adjust the configuration level using a user interface. If the level should be changed, the configuration level is set to an input level received, for example, via a user interface. After setting the new values, the method returns to the beginning to repeat the next weld instance. According to one embodiment, only the welding time for the most recent single weld is stored (recorded) in the memory. The weld times previously recorded for each previous weld are stored in an accumulated manner as a single accumulated weld time. "(see, e.g., the flow chart of FIG. 4).

Referring now to FIG. 5, a welding system 300 is illustrated. The welding system 300 may include a welding cap 302, which may be similar to the cap 100 described above. The system 300 may also include one or more welding power sources and computing devices 310, such as

power sources

306, 308. According to an aspect, the welding cap 302 may be in communication with the

welding power sources

306, 308 and/or the computing device 310. For example, the welding cap 302 may report the welding time to the

power sources

306, 308 or the computing device 310. Further, the welding caps may receive adjustment values or reset commands from the

power sources

306, 308 or the computing device 310.

In one embodiment, more than one analog optical sensor is provided to determine the minimum light intensity value to begin counting arc times. According to one embodiment, different base units may be used to record the arc time, e.g. seconds per day or hours per day. In one embodiment, another type of sensor, such as a high resolution camera 109 and appropriate software, may be provided to calculate the relative light intensity between the arc and the background environment. In one embodiment, the arc time data is stored external to the auto-darkening filter rather than internal to the auto-darkening filter. In one embodiment, the settings (e.g., threshold light intensity values) and the memory data may be adjusted externally rather than using an auto-darkening filter user interface.

According to one embodiment, the trigger starts collecting data when the threshold light intensity value is higher than a minimum value set by the user. The light intensity value is determined by an analog optical sensor and may be above a threshold value of a digital optical sensor. For example, if several pre-welds are made at the weld site to hold the two parts together, the lens filter may darken, but these welds may or may not exceed the minimum light intensity value at which data collection begins, depending on how high the setting is.

According to one embodiment, instead of (or in addition to) an analog optical sensor, a magnetic field sensor 107 may be used to detect the presence of an arc. The magnetic field sensor 107 detects a magnetic field (or a change in a magnetic field) generated by the arc. As with the optical sensor, a threshold level may be set for the magnetic field level detected by the magnetic sensor to trigger the counting of the arc duration.

One embodiment includes a weld cap having an analog optical sensor configured to detect incident light and output a signal indicative of a light intensity level of the incident light. The weld cap also includes control circuitry configured to receive a signal from the analog optical sensor. The control circuitry is also configured to record a weld time based on the signal from the analog optical sensor and the configured light level. The weld time corresponds to the duration of time that the light intensity level indicated by the analog optical sensor exceeds the configured light level. In one embodiment, the level of configured light is user selectable. In one embodiment, the control circuitry includes a counter configured to determine the weld time. According to various embodiments, the counter may be hardware-based or software-based. In one embodiment, the welding cap includes a transceiver configured to transmit (wired or wirelessly) information (e.g., welding time) to a welding power source or a computing device. In one embodiment, the welding cap comprises an auto-dimming panel.

One embodiment includes a welding helmet having an arc detection system configured to detect one or more welding arcs that occur during one or more welding operations. The welding cap also includes control circuitry configured to brighten or dim the lens components of the welding cap based at least in part on the one or more welding arcs detected by the arc detection system. The control circuitry is further configured to record an amount of time duration that the one or more welding arcs are present based on the detection system. The control circuitry is further configured to record only times of one or more welding arcs detected by the arc detection system that have an arc intensity value greater than a predetermined threshold arc intensity. The welding cap further comprises a storage device configured to store a sum of the durations of the welding arcs over a defined period of time. In one embodiment, the predetermined threshold arc intensity is user selectable. In one embodiment, the arc detection system includes at least one analog optical sensor configured to detect incident light and output at least one signal indicative of an arc intensity level being a certain arc light intensity level. In an embodiment, the arc detection system comprises at least one magnetic field sensor configured to detect a magnetic field or a change in a magnetic field generated by one or more welding arcs and to output at least one signal indicating that the arc strength level is a certain arc magnetic field strength level. In one embodiment, a welding cap includes a transceiver configured to transmit to a welding power source or a computing device at least an amount of time duration that one or more welding arcs are present based on an arc detection system.

One embodiment includes a welding helmet having an arc detection system configured to detect a plurality of welding arcs occurring during one or more welding operations. The welding helmet also includes control circuitry configured to brighten or dim a lens component of the welding helmet based at least in part on the plurality of welding arcs detected by the arc detection system and to determine a duration of a most recent welding arc of the plurality of welding arcs detected by the arc detection system. The control circuitry is further configured to record a duration of a most recent welding arc of the plurality of welding arcs detected by the arc detection system, the most recent welding arc having a corresponding light intensity value greater than a predetermined threshold light intensity. The welding cap also includes a storage device configured to store a total duration of each time period (e.g., a day, a week, a month, etc.) for at least a portion of the plurality of welding arcs detected by the arc detection system. The total duration of each time period of a portion of the plurality of welding arcs detected by the arc detection system may comprise a sum of the durations of the welding arcs of each time period of the portion of the plurality of welding arcs. In one embodiment, the predetermined threshold arc light intensity is user selectable. In one embodiment, the control circuitry includes a counter configured to determine a duration of a most recent welding arc of the plurality of welding arcs detected by the arc detection system. The arc detection system includes at least one of an analog optical sensor, a magnetic field sensor, or a high resolution camera that detects a plurality of welding arcs occurring during one or more welding operations.

One embodiment includes a welding helmet having an arc detection system configured to detect one or more welding arcs that occur during one or more welding operations. The welding cap also includes control circuitry configured to brighten or dim the lens components of the welding cap based at least in part on the one or more welding arcs detected by the arc detection system and configured to allow a variable duration of the detected one or more welding arcs to be reset by the arc detection system. The control circuitry is further configured to allow the variable duration of the detected one or more welding arcs to be reset by the arc detection system for welding arcs of the one or more welding arcs having an arc intensity value greater than the predetermined arc intensity. The welding cap also includes a memory device configured to store a variable duration of one or more welding arcs that are detected by the arc detection system that can be reset. The first date provides a reference point that is associated with the earliest recordable sum of the variable durations of the one or more welding arcs per day. The second date is the earliest date that the user elects to reset the variable duration of one or more welding arcs per day. The third date is the latest date that the user selected to reset the variable duration of one or more welding arcs per day. In an embodiment, the control circuitry includes a counter configured to determine a variable duration of one or more welding arcs in which the detected arc intensity value is greater than the predetermined arc intensity. In one embodiment, the predetermined arc intensity is user selectable. In one embodiment, the arc detection system includes at least one of an analog optical sensor, a magnetic field sensor, or a high resolution camera configured to detect one or more welding arcs occurring during one or more welding operations. In one embodiment, the welding cap further includes a transceiver configured to transmit at least a variable duration of one or more welding arcs having a detected arc intensity value greater than a predetermined arc intensity to a welding power source or a computing device.

Any controller, control circuit, or control circuitry in various embodiments of the invention may include, for example, one or more of the following: a microprocessor, a microcontroller, a Programmable Logic Circuit (PLC), a Digital Signal Processor (DSP), digital logic gates, Random Access Memory (RAM), Read Only Memory (ROM), digital counters, a user interface (e.g., a touch screen display), and a network interface. According to other embodiments, other elements of a controller, control circuit, or control circuitry may also be used.

The above examples are merely illustrative of several possible embodiments of various aspects of the present invention, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, circuits, etc.), the terms (including a reference to a "means") used to describe such components are intended to correspond, unless otherwise indicated, to any component (e.g., hardware, software, or combination thereof) which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated implementations of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. In addition, to the extent that the terms "includes", "including", "includes", "having", "has", "with", or variants thereof are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising".

This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to practice embodiments of the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

The best mode for carrying out the invention has been described herein for the purpose of illustrating the best mode known to the applicant. The examples are merely illustrative and are not meant to limit the invention, as measured by the scope and spirit of the claims. The invention has been described with reference to various embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to embrace all such modifications and variations that fall within the scope of the appended claims or the equivalents thereof.

Claims

1. A welding cap, comprising:

an analog optical sensor configured to detect incident light and output a signal indicative of a light intensity level; and

a control circuit configured to:

receiving a signal from the analog optical sensor, and

recording a weld time based on a signal from the analog optical sensor and a configured light level, wherein the weld time corresponds to a duration of time that a light intensity level indicated by the analog optical sensor exceeds the configured light level.

2. The welding cap of claim 1, wherein the configured light level is user-selectable.

3. The welding cap of claim 1, wherein the control circuitry comprises a counter configured to determine a weld time.

4. The welding cap of claim 1, further comprising a transceiver configured to transmit at least the welding time to a welding power source or a computing device.

5. The welding helmet of claim 1, wherein the welding helmet comprises an auto-darkening visor.

6. A welding cap, comprising:

an arc detection system configured to detect one or more welding arcs occurring during one or more welding operations;

control circuitry configured to brighten or dim a lens assembly of the welding helmet based at least in part on the one or more welding arcs detected by the arc detection system and to record an amount of time duration that the one or more welding arcs are present in accordance with the arc detection system, wherein the control circuitry is configured to only record times of the one or more welding arcs for which an arc intensity value detected by the arc detection system is greater than a predetermined threshold arc intensity; and

a storage device configured to store a sum of durations of welding arcs during a defined time period.

7. The welding cap of claim 6, wherein the predetermined threshold arc intensity is user-selectable.

8. The welding cap of claim 6, wherein the arc detection system comprises at least one analog optical sensor configured to detect incident light and output at least one signal indicative of an arc intensity level being an arc light intensity level.

9. The welding cap of claim 6, wherein the arc detection system comprises at least one magnetic field sensor configured to detect a magnetic field or a change in a magnetic field generated by the one or more welding arcs and configured to output at least one signal indicative of an arc intensity level being an arc magnetic field intensity level.

10. The welding cap of claim 6, further comprising a transceiver configured to transmit at least an amount of time duration that one or more welding arcs are present to a welding power source or a computing device as a function of the arc detection system.

11. A welding cap, comprising:

an arc detection system configured to detect a plurality of welding arcs occurring during one or more welding operations;

control circuitry configured to: brightening or darkening a lens assembly of the welding cap based at least in part on the plurality of welding arcs detected by the arc detection system, determining a duration of a most recent welding arc of the plurality of welding arcs detected by the arc detection system, and recording the duration of a most recent welding arc of the plurality of welding arcs having a respective arc light intensity value detected by the arc detection system that is greater than a predetermined threshold arc light intensity; and

a storage device configured to store a total duration of each time period of a portion of the plurality of welding arcs detected by the arc detection system, wherein the total duration of each time period of the portion of the plurality of welding arcs detected by the arc detection system comprises a sum of the durations of the welding arcs of each time period of the portion of the plurality of welding arcs.

12. The welding cap of claim 11, wherein the period of time is one of a day, a week, or a month.

13. The welding cap of claim 11, wherein the predetermined threshold arc light intensity is user-selectable.

14. The welding cap of claim 11, wherein the control circuitry comprises a counter configured to determine a duration of a most recent welding arc of the plurality of welding arcs detected by the arc detection system.

15. The welding cap of claim 11, wherein the arc detection system comprises at least one of an analog optical sensor, a magnetic field sensor, or a high resolution camera configured to detect a plurality of welding arcs occurring during one or more welding operations.

16. A welding cap, comprising:

control circuitry configured to brighten or dim a lens assembly of the welding helmet based at least in part on the one or more welding arcs detected by the arc detection system and configured to allow a variable duration of the one or more welding arcs detected to be reset by the arc detection system for welding arcs of the one or more welding arcs having an arc intensity value greater than a predetermined arc intensity; and

a storage device configured to store variable durations of the one or more welding arcs detected by the arc detection system, the variable durations being resettable, wherein a first date provides a reference point associated with an earliest recordable sum of the variable durations of the one or more welding arcs on a day, a second date is an earliest date that a user selects to reset the variable durations of the one or more welding arcs on a day, and a third date is a latest date that a user selects to reset the variable durations of the one or more welding arcs on a day.

17. The welding cap of claim 16, wherein the control circuitry comprises a counter configured to determine a variable duration of the one or more welding arcs for which the detected arc intensity value is greater than a predetermined arc intensity.

18. The welding cap of claim 16, wherein the predetermined arc intensity is user selectable.

19. The welding cap of claim 16, wherein the arc detection system comprises at least one of an analog optical sensor, a magnetic field sensor, or a high resolution camera configured to detect one or more welding arcs occurring during one or more welding operations.

20. The welding cap of claim 16, further comprising a transceiver configured to transmit at least a variable duration of one or more welding arcs having a detected arc intensity value greater than a predetermined arc intensity to a welding power source or a computing device.