JP2024067691A - Welding system and welding method using the same - Google Patents

Abstract

[Problem] To provide a welding system that allows a welding operator to easily call up and set desired welding conditions without making a mistake during welding. [Solution] A welding system 70 includes a welding power source 2, a remote control device 1, and a torch 4. The remote control device 1 has a measurement unit 13 that measures the acceleration applied to the remote control device 1, and a control unit 14 that determines the attitude of the remote control device 1 with respect to the direction of gravity based on the output value of the measurement unit 13. In the welding power source 2, different attitudes of the remote control device 1 and different welding conditions of the welding power source 2 are stored as a condition table in association with each other. When the attitude of the remote control device 1 is changed from one attitude to another, the welding conditions read out by the welding power source 2 are changed from one welding condition associated with one attitude to another welding condition associated with the other attitude. [Selected Figure] FIG. 1

Description

This disclosure relates to a welding system and a welding method using the same.

Conventionally, when adjusting welding parameters in a welding power source due to changes in the material, welding posture, purpose, etc. of the object to be welded (hereinafter sometimes referred to as the work), adjustments are made on the operation unit of the welding power source or using a remote control device. In particular, when the work is large, the welding operator may move alone without moving the welding power source. As a result, the welding operator may be separated from the welding power source. Therefore, in order to reduce the movement time required for the welding operator to adjust parameters, a technology has been disclosed that allows the welding operator to adjust parameters using a remote control device placed at hand (see, for example, Patent Document 1).

However, when using a wireless remote control device such as that shown in Patent Document 1, the welding operator adjusts the welding parameters while looking at the operation unit and display unit of the remote control device before welding, and then performs the welding work. During welding work, the welding operator wears a welding protective mask (hereinafter simply referred to as a protective mask) to block light, so he or she cannot see the operation unit and display unit of the remote control device, making it difficult to make adjustments.

Therefore, a technology has been proposed in which a specific position of the remote control device is stored in advance in correspondence with a welding current switch mode or a welding voltage switch mode, and when the position of the remote control device becomes the corresponding switch mode, the welding current or welding voltage can be changed (see, for example, Patent Document 2).

Patent Document 3 also discloses a configuration in which a welding torch (hereinafter simply referred to as a torch) is provided with a sensor unit, specifically an acceleration sensor, that detects its own tilt information, and the tilt information is stored in association with welding information, for example, a registration number for preset permanent conditions. During welding work, the sensor unit detects the tilt information of the torch, calls up the corresponding welding information, and the welding operator can perform welding under the desired conditions without having to input it himself.

Japanese Patent Application Laid-Open No. 10-305366 International Publication No. 2017/043058 International Publication No. 2019/009012

However, as mentioned above, since the welding operator wears a protective face mask during welding, the operation section and display section of the remote control device cannot be seen. In addition, a high current flows through the welding wire held by the torch during welding. To ensure work safety, welding operators often wear thick gloves. For this reason, in the configuration disclosed in Patent Document 2, even if the position of the remote control device is changed to make it possible to change the welding current or welding voltage, it can be difficult to operate the volume or switch provided in the remote control circuit.

Depending on the shape and size of the workpiece, the torch position may be changed multiple times or in various directions during welding. In such cases, the configuration disclosed in Patent Document 3, which associates the torch position with the welding conditions on a one-to-one basis, may call up the wrong welding conditions. Also, in order to call up the desired welding conditions, it was necessary to interrupt welding and change the torch position. For this reason, it may not be suitable for continuous welding of workpieces.

The present disclosure has been made in consideration of these points, and its purpose is to provide a welding system and a welding method using the same that allow a welding operator to easily call up and set the desired welding conditions without making mistakes while welding.

In order to achieve the above object, the welding system according to the present disclosure is a welding system including at least a welding power source, a remote control device configured to be able to communicate with the welding power source, and a torch electrically connected to the welding power source, wherein the remote control device has at least a measurement unit that measures acceleration applied to the remote control device, a control unit that determines the attitude of the remote control device based on the direction of gravity is provided in at least one of the welding power source and the remote control device, different attitudes of the remote control device and different welding conditions of the welding power source are stored in association with each other, and when the attitude of the remote control device is changed from one attitude to another, the welding conditions read out to the welding power source are changed from one welding condition associated with the one attitude to another welding condition associated with the other attitude.

According to the present disclosure, during welding, the welding operator can easily recall the desired welding conditions and set them in the welding power source without making a mistake. This allows welding to continue seamlessly on the workpiece.

1 is a schematic configuration diagram of a welding system according to an embodiment. FIG. 2 is a schematic diagram showing the appearance of a remote control device. 3 is a flowchart showing a welding method according to an embodiment. 3 is a schematic diagram showing the relationship between the attitude of the remote control device and the direction of gravity. FIG. 13 is another schematic diagram showing the relationship between the attitude of the remote control device and the direction of gravity. FIG. 13 is yet another schematic diagram showing the relationship between the attitude of the remote control device and the direction of gravity. FIG. 13 is an example of a condition table in which the attitude of the remote control device and welding conditions are associated with each other. 13 is an example showing a display unit of the remote control device after changing its attitude. 4A and 4B are diagrams illustrating the relationship between the attitude of the remote control device and the direction of gravity. 13 is another diagram showing the relationship between the attitude of the remote control device and the direction of gravity. FIG.

Embodiments of the present disclosure will be described below with reference to the drawings. Note that the following description of the preferred embodiments is merely illustrative in nature and is not intended to limit the present disclosure, its applications, or its uses.

(Embodiment)
[Welding system configuration]
Fig. 1 shows a schematic configuration diagram of a welding system according to an embodiment, and Fig. 2 shows a schematic diagram of the appearance of a remote control device. In the following description, the direction in which gravity acts is referred to as the gravity direction.

As shown in FIG. 1, the welding system 70 has a welding power source 2, a wire feeder 3, and a torch 4. The welding power source 2 and the wire feeder 3 are connected by a power cable 51, and the welding power source 2 and the torch 4 are connected by a power cable 52. Furthermore, a remote control device 1 that can remotely control the welding power source 2 by a wireless method or the like is placed in a position away from the welding power source 2.

The welding power source 2 converts the power required for welding and supplies it to the torch 4. The welding power source 2 has an operation unit 21, a memory unit 22, a control unit 24, a wireless communication unit 26, and an output unit 28.

The operation unit 21 has buttons and a rotary encoder with a switch (not shown). By operating the buttons and rotary encoder with a switch provided on the operation unit 21, the welding operator can read the welding conditions stored in the memory unit 22 into the control unit 24 and perform the desired welding process. In addition, the values of each parameter in the welding conditions can be changed and modified. Note that a display unit may be provided on the welding power source 2 so that the welding operator can check the input welding conditions and welding parameters.

The control unit 24 is composed of one or more CPUs (Central Processing Units), and reads the welding conditions used in the welding operation from the memory unit 22, etc., and sets them in the welding power source 2. The control unit 24 also controls multiple parameters that determine the welding conditions.

The storage unit 22 is composed of semiconductor memory such as RAM (Random Access Memory) or ROM (Read Only Memory), and stores the above-mentioned welding conditions and parameters for each welding condition. The storage unit 22 may be composed of an HDD (Hard Disk Drive) or SSD (Solid State Drive), etc. The storage unit 22 may also be a functional block of the CPU, that is, a ROM or RAM built into the CPU. The storage unit 22 also stores the welding conditions in association with the position of the remote control device 1. This will be described in detail later.

The wireless communication unit 26 transmits and receives data to and from the remote control device 1 via a wireless communication antenna 27. The output unit 28 outputs power and control signals corresponding to the settings of the control unit 24 to the feed device 3 and the torch 4.

The remote control device 1 also has an operation unit 11, a memory unit 12, a measurement unit 13, a control unit 14, a display unit 15, a wireless communication unit 16, and an antenna 17. The hardware configurations of the control unit 14 and the memory unit 12 are similar to the hardware configurations of the control unit 24 and the memory unit 22, respectively.

The operation unit 11 has buttons and a rotary encoder with a switch. By operating the buttons and rotary encoder with a switch of the operation unit 11, the welding operator can change and modify the values of each parameter of the welding power source 2 under the desired welding conditions.

As shown in FIG. 2, the operation unit 11 is composed of a HOME button 11a, operation buttons 11b to 11e, and switch-equipped rotary encoders 11f and 11g, and receives operation contents from a welding operator. For example, the welding operator can switch the display unit 15 to the initial screen by operating the HOME button 11a.

Operation buttons 11b to 11e correspond to operations for reading and deciding welding conditions, and for selecting welding parameters to be changed. Switched rotary encoders 11f and 11g correspond to operations for changing the specific values of selected welding parameters. The items selected and values entered by operating operation unit 11 are configured to be displayed in real time on display unit 15. This allows the welding operator to read out the desired welding conditions while checking the input contents, and to change the welding conditions, etc.

As will be described later, the welding conditions can also be changed by the welding operator changing the position of the remote control device 1. In this case, by operating at least one of the HOME button 11a, the operation buttons 11b to 11e, and the switch-equipped rotary encoders 11f and 11g, the position of the remote control device 1 can be changed to confirm the changed welding conditions, or to make it possible to change the set values of the welding parameters in the welding conditions, such as the welding current and welding voltage.

The memory unit 12 stores welding parameter information and communication parameter information.

The measurement unit 13 has an acceleration sensor 18 and can measure the acceleration applied to the remote control device 1. The acceleration sensor 18 is composed of a known three-axis (X-axis, Y-axis, Z-axis) acceleration sensor. The acceleration sensor 18 detects the acceleration applied to the remote control device 1 in each of the three axial directions when the attitude of the remote control device 1 changes. Note that one of the three axial directions is the direction of gravity, and the other two directions are each perpendicular to the direction of gravity, and the two directions are perpendicular to each other. Note that the acceleration sensor 18 detects acceleration at a predetermined sampling frequency and outputs the detected value to the control unit 14.

The type of acceleration sensor 18 is not limited to those described above. It is sufficient if it can detect information that can determine the direction of gravity and the attitude of the remote control device 1 based on that direction. For example, it may be a gyro sensor or a sensor that integrates an acceleration sensor and a gyro sensor.

The control unit 14 uses the output value of the acceleration sensor 18 to perform calculations to determine the attitude of the remote control device 1.

The calculation for determining the attitude of the remote control device 1 may be performed by the control unit 24 of the welding power source 2. In this case, the output value of the acceleration sensor 18 is transmitted to the welding power source 2 via the wireless communication unit 16 and antenna 17 of the remote control device 1. The control unit 14 receives this output value and performs a calculation for determining the attitude of the remote control device 1.

The display unit 15 is configured, for example, with a liquid crystal display. The display unit 15 may be a touch panel with an input function. The display unit 15 displays information based on a signal from the control unit 14. As described later, the display unit 15 also displays the welding condition number selected according to the attitude of the remote control device 1, or the values of the welding parameters for that welding condition number.

Wireless signals are sent and received between the welding power source 2 and the remote control device 1. In the remote control device 1, wireless signals are sent and received by the wireless communication unit 16 and antenna 17. The control unit 14 controls the sending and receiving of wireless signals by the wireless communication unit 16 and antenna 17. Note that in this embodiment, the communication method between the remote control device 1 and the welding power source 2 is wireless, but if operations are performed at a relatively close distance and wiring is not a concern, the communication method between the remote control device 1 and the welding power source 2 may be wired.

The feeder 3 is configured to hold the welding wire and feed the welding wire forward or backward to the workpiece 60 at a set feed amount (feed speed). This feed amount is determined according to the moving average value of the welding current set in the welding conditions.

The torch 4 holds the welding wire and supplies the power output from the output section 28 of the welding power source 2 to the welding wire. An arc is generated between the tip of the welding wire to which power has been supplied and the welding surface of the workpiece 60, and the workpiece 60 is welded. The torch 4 is provided with a switch 4a, which, when operated, is configured to supply welding power from the welding power source 2 to the welding wire or to stop the supply of power.

The torch 4 is also provided with gas piping (not shown), and is configured so that during welding, an inert gas such as argon is sprayed as a shielding gas onto the welding surface of the workpiece 60 onto which the arc is irradiated, or a gas containing several percent to several tens of percent carbon dioxide is sprayed onto the welding surface.

The welding operator uses a welding power source 2 and a remote control device 1 that has established wireless communication with the welding power source 2. The welding operator holds the remote control device 1 in the hand not holding the torch 4, and in the hand holding the remote control device 1, and performs welding on the workpiece 60. When welding, if the welding conditions need to be changed, the remote control device 1 is operated in a manner described later. Also, if the welding parameters in the welding conditions need to be changed, the operation unit 11 of the remote control device 1 is operated.

[Welding method]
As described above, the remote control device 1 determines its own attitude based on the output value of the acceleration sensor 18 built into the remote control device 1 itself.

The welding system 70 shown in this embodiment utilizes this to allow the welding operator to easily and reliably change the welding conditions during welding. This is further explained below with reference to Figure 3.

Figure 3 is a flowchart showing a welding method according to an embodiment. Figures 4A to 4C are schematic diagrams showing the relationship between the attitude of the remote control device and the direction of gravity.

Figure 5 is an example of a condition table that associates the position of the remote control device with welding conditions. Figure 6 is an example showing the display of the remote control device after changing the position.

In the following description, the surface on which the operation unit 11 and the display unit 15 of the remote control device 1 are provided is called the first surface 1a, the side surface in the longitudinal direction of the remote control device 1 is called the second surface 1b, and the side surface in the lateral direction is called the third surface 1c. The direction along the second surface 1b is called the first direction, and the direction along the third surface 1c is called the second direction. In the remote control device 1 shown in Figures 4A to 4C, the second surface 1b is each of the two side surfaces facing in the second direction, and the third surface 1c is each of the two side surfaces facing in the first direction. However, this is not particularly limited, and for example, one of the two second surfaces 1b may be called the second surface 1b1 and the other may be called the second surface 1b2 to distinguish them. As will be described later, the way in which these are distinguished will differ depending on which surface is used as the reference surface when identifying the posture of the remote control device 1.

First, multiple welding conditions are registered in the welding power source 2. At that time, the welding conditions are registered in a state in which they are associated with the posture of the remote control device 1 (step S1).

Specifically, the welding conditions are input by operating the operation unit 21, and the input contents are stored in the memory unit 22. Alternatively, the welding conditions are input from outside via the wireless communication unit 16 and the antenna 17, and the input contents are stored in the memory unit 22. At this time, a number is assigned to each different welding condition.

Furthermore, the control unit 24 edits the welding conditions, which are assigned a specific number, in a condition table by associating them with a specific posture of the remote control device 1, and stores the edited contents (see FIG. 5) in the memory unit 22.

For example, as shown in FIG. 4A, the position in which the first surface 1a of the remote control device 1 is arranged to intersect with the direction of gravity is defined as the first position A, and the output value of the acceleration sensor 18 corresponding to the first position A is associated with welding condition 1 and edited in the condition table. In this embodiment, welding condition 1 is configured by presetting the welding current, welding voltage, and feed amount of welding wire (not shown) when the welded surface of the workpiece 60 faces upward as shown in FIG. 1 (hereinafter, sometimes referred to as downward welding).

As shown in FIG. 4A, in the first position A, the first direction, the second direction, and the direction of gravity are mutually perpendicular. Note that the first position A can be further divided into two cases, where the first surface 1a of the remote control device 1 is positioned facing upward so as to intersect with the direction of gravity (the direction of gravity is shown by a solid line in FIG. 4A), and where it is positioned facing downward (the direction of gravity is shown by a dashed line in FIG. 4A).

In this specification, "orthogonal," "parallel," or "same" means orthogonal, parallel, or the same, including the manufacturing tolerances and assembly tolerances of the welding system 70 and each of the components that make up the system, and does not mean that the objects being compared are orthogonal, parallel, or the same in the strict sense.

As shown in FIG. 4B, the position in which the remote control device 1 is placed so that the first direction is parallel to the direction of gravity is defined as the second position B, and the output value of the acceleration sensor 18 corresponding to the second position B is associated with the welding condition 2 and edited in the condition table. In this embodiment, the welding condition 2 is configured by presetting the welding current, welding voltage, and feed amount of the welding wire (not shown) when the welded surface of the workpiece 60 is parallel to the direction of gravity (hereinafter sometimes referred to as vertical welding). The second position B is further divided into two types, and the direction of gravity is shown in FIG. 4B by a solid line and a dashed line, respectively.

As shown in FIG. 4C, the position where the remote control device 1 is placed so that the second direction is parallel to the direction of gravity is defined as the third position C, and the output value of the acceleration sensor 18 corresponding to the third position C is associated with the welding condition 3 and edited in the condition table. In this embodiment, the welding condition 3 is configured by presetting the welding current, welding voltage, and feed amount of the welding wire (not shown) when the welded surface of the workpiece 60 is parallel to the direction of gravity, while the direction in which the torch 4 is moved intersects with the direction of gravity (hereinafter sometimes referred to as horizontal welding). The third position C is further divided into two types, and the direction of gravity is illustrated in FIG. 4C by a solid line and a dashed line, respectively.

The relationship between the position of the remote control device 1 and the welding conditions is not particularly limited to those shown in Figures 4A to 4C. For example, welding condition 1 may be the welding condition for flat welding and butt welding, while welding condition 2 may be the welding condition for vertical welding and butt welding, and welding condition 3 may be the welding condition for flat welding and fillet welding.

Six or more welding conditions may be registered. In this case, the relationship between the attitude of the remote control device 1 and the welding conditions is specified in more detail. For example, the normal to the first surface 1a of the remote control device 1, or the first direction, or the second direction is inclined relative to the direction of gravity by a range exceeding the angle deviation described later. The attitude of the remote control device 1 in this case may be associated with another welding condition, for example, a condition for fillet welding of a T-joint, and edited in the condition table. Alternatively, the other welding condition may be the welding condition when the welded surface of the workpiece 60 is inclined at a predetermined angle θ (0°<θ<90°) relative to the direction of gravity.

When changing the position of the remote control device 1, it is preferable that the welding worker can clearly distinguish between the different positions while wearing the protective mask. For this reason, it is desirable to give the structure of the remote control device 1 a feature that is not point symmetric so that the welding worker can recognize the position of the remote control device 1 by touch. For example, on the first surface 1a, the operation buttons 11b to 11e and the switch-equipped rotary encoders 11f, 11g, etc. may be arranged so as not to be point symmetric. Alternatively, the length of the second surface 1b along the first direction and the length of the third surface 1c along the second direction may be changed to set them so as not to be point symmetric.

Next, the welding operator approaches the workpiece 60 holding the remote control device 1 and the torch 4. Once preparations are complete, the welding operator operates the operation unit 11 of the remote control device 1 to set the welding power source 2 to a control mode (playback mode) that allows remote operation. Note that once the playback mode is set, changes to the welding parameters are prohibited.

The welding operator then operates the operation unit 11 of the remote control device 1 to set the desired welding conditions in the control unit 24 of the welding power source 2. If necessary, the welding operator changes the values of the welding parameters for the welding conditions (step S2). When changing the welding parameters, at least one of the operation buttons 11b to 11e and the switch-equipped rotary encoders 11f and 11g is operated. Since welding has not yet started when step S2 is executed, the welding operator can remove the protective mask (not shown) and visually check the display unit 15 of the remote control device 1.

After performing step S2, the welding operator operates the remote control device 1 to operate the welding power source 2. Putting on a protective face mask, the welding operator brings the torch 4 close to the surface to be welded of the workpiece 60, and operates the switch 4a provided on the torch 4 to generate an arc and start welding (step S3). The torch 4 is moved along a predetermined weld line (not shown) on the surface to be welded of the workpiece 60 to proceed with the welding.

Next, the welding operator judges whether or not it is necessary to change the welding conditions during welding (step S4). If the judgment result in step S4 is negative, that is, if there is no need to change the welding conditions, the welding is continued as is, and after moving the torch 4 to the end of the weld line, the switch 4a provided on the torch 4 is operated to extinguish the torch and end the welding (step S8). Furthermore, the welding power source 2 is stopped, and the entire process is completed.

The welding conditions may need to be changed, for example, when the shape of the workpiece 60 changes midway, causing flat welding to change to vertical welding, or vice versa. Also, the direction of the weld line may change, causing vertical welding to change to horizontal welding, or vice versa. Of course, there may be other cases where the welding conditions need to be changed. For example, this may include a case where the workpiece 60 is a composite material and the material changes midway along the weld line.

On the other hand, if the determination result in step S4 is positive, that is, if the welding conditions need to be changed, the process proceeds to step S5. The welding operator moves the remote control device 1 to change the position of the remote control device 1 to the desired position. In this way, the welding conditions associated with that position are read out from the condition table stored in the memory unit 22 of the welding power source 2 by the control unit 24 (step S5). However, after step S5 is executed, the welding conditions are not changed immediately, and the change to the read welding conditions is finalized after step S6, which will be described later, is executed.

When welding is being performed continuously on the workpiece 60, step S5 is executed while the welding operator is still wearing the protective mask. In the example shown in Figures 4A to 4C, the welding operator can recognize the position of the remote control device 1 even while wearing the protective mask. In other words, the welding operator can reliably recognize that the welding conditions have been changed.

However, if more than three welding conditions are associated with different positions of the remote control device 1, the welding operator may not be able to determine whether the position of the remote control device 1 has changed while wearing the protective face mask.

In such a case, it is necessary to inform the welding operator that the welding conditions will be changed by another method. For example, the remote control device 1 may be provided with a voice notification unit (not shown) to notify the welding operator that the welding conditions will be changed. Alternatively, the remote control device 1 may be provided with a vibrator (not shown) that vibrates in conjunction with the change in the welding conditions to notify the welding operator that the welding conditions will be changed. The welding operator may be notified that the welding conditions will be changed by a method other than these.

As shown in FIG. 6, the display unit 15 displays the changed welding condition number and the main welding parameters. If it is acceptable to temporarily extinguish the arc by operating the switch 4a provided on the torch 4, the welding operator can remove the protective mask and visually check the welding condition number and other information displayed on the display unit 15.

Following step S5, as described above, the welding operator operates at least one of the HOME button 11a, the operation buttons 11b to 11e, and the rotary encoders with switches 11f and 11g to finalize the changed welding conditions (step S6). At this time, the welding parameter setting may be changed by operating at least one of the operation buttons 11b to 11e and further operating one of the rotary encoders with switches 11f and 11g.

As described above, if the display unit 15 is a touch panel, the display unit 15 can be considered as part of the operation unit 11. In this case, in step S6, the changed welding conditions may be confirmed by touching the display unit 15.

After step S6 is performed, the welding operator resumes welding under the changed welding conditions (step S7). Then, the process returns to step S4, and the series of steps S4 to S8 are repeatedly performed until the determination result of step S4 becomes negative.

[Tolerance of remote control device attitude judgment]
7A and 7B are diagrams showing the relationship between the attitude of the remote control device and the direction of gravity, respectively. Fig. 7A shows a case where the first direction is inclined at an angle θ1 with respect to the direction of gravity, and Fig. 7B shows a case where the second direction is inclined at an angle θ2 with respect to the direction of gravity.

When a welding operator holds the remote control device 1 in his/her hand and changes its posture, it is difficult to make it completely match the postures shown in, for example, Figures 4A to 4C. For this reason, when the control unit 14 of the remote control device 1 determines the posture of the remote control device 1 based on the output value of the acceleration sensor 18, the posture is allowed to deviate from the set position within a certain range. In this embodiment, this position deviation is expressed as an angle deviation from the direction of gravity.

In the example shown in FIG. 7A, the first direction of the remote control device 1 is tilted at an angle θ1 with respect to the direction of gravity from the second attitude B. If this angle θ1 is equal to or smaller than a preset threshold value θth1, the control unit 14 is configured to determine that the attitude of the remote control device 1 is the second attitude B.

On the other hand, if the angle θ1 exceeds the threshold value θth1, the control unit 14 is configured to determine that the attitude of the remote control device 1 is not the second attitude B. In this case, depending on the value of the angle θ1, the control unit 14 may determine that the attitude of the remote control device 1 is the third attitude C.

In the example shown in FIG. 7B, the second direction of the remote control device 1 is tilted at an angle θ2 with respect to the direction of gravity from the third attitude C. If this angle θ2 is equal to or smaller than a preset threshold value θth2, the control unit 14 is configured to determine that the attitude of the remote control device 1 is the third attitude C.

On the other hand, if the angle θ2 exceeds the threshold value θth2, the control unit 14 is configured to determine that the attitude of the remote control device 1 is not the third attitude C. In this case, depending on the value of the angle θ2, the control unit 14 may determine that the attitude of the remote control device 1 is the second attitude B.

If the threshold value θth1 or the threshold value θth2 is set to a value greater than 45 degrees, the control unit 14 cannot determine whether the attitude of the remote control device 1 is the second attitude B, the third attitude C, or another attitude, for example, an attitude not associated with the welding conditions. Therefore, in this embodiment, the threshold values θth1 and θth2 are each set to 30 degrees. However, this is not limited, and for example, the threshold values θth1 and θth2 may be set to 30 degrees or more and 40 degrees or less, respectively.

The lower limits of the thresholds θth1 and θth2 are set appropriately depending on the performance of the acceleration sensor 18 and the hand shake of the welding operator. For example, the lower limit can be set to 10 degrees.

In addition, depending on the shape of the remote control device 1, particularly the length of the second surface 1b along the first direction and the length of the third surface 1c along the second direction, the threshold values θth1 and θth2 may each be set to a different value.

It goes without saying that a similar tolerance and threshold value for the angle between the normal to the first surface 1a and the direction of gravity are also set.

In addition, when the welding operator is not operating the remote control device 1, in order to prevent malfunction, the setting screens for each operation may be locked using a lock switch (not shown) or a lock command (not shown) so that operation of the HOME button 11a, operation buttons 11b to 11e, and switch-equipped rotary encoders 11f and 11g is not accepted.

[Effects, etc.]
As described above, the welding system 70 according to this embodiment includes at least a welding power source 2, a remote control device 1 configured to be able to communicate with the welding power source 2, and a torch 4 electrically connected to the welding power source 2.

The remote control device 1 has at least a measurement unit 13 that measures the acceleration applied to the remote control device 1, and a control unit 14.

The control unit 14 determines the posture of the remote control device 1 with respect to the direction of gravity based on the output value of the measurement unit 13. However, the control unit 24 provided in the welding power source 2 may determine the posture of the remote control device 1 with respect to the direction of gravity based on the output value of the measurement unit 13. In this case, the welding power source 2 receives the output value of the measurement unit 13 transmitted from the remote control device 1, and the control unit 24 determines the posture of the remote control device 1 with respect to the direction of gravity based on the output value. At least one of the control unit 14 and the control unit 24 needs to have a calculation function for determining the posture of the remote control device 1. In other words, either one of them may have the calculation function, or both the control unit 14 and the control unit 24 may have the calculation function.

In the memory unit 22 of the welding power source 2, different positions of the remote control device 1 are associated with different welding conditions of the welding power source 2 and stored as a condition table.

When the position of the remote control device 1 is changed from one position to another position different from the one position, the welding conditions read by the control unit 24 of the welding power source 2 are changed from one welding condition associated with the one position to another welding condition associated with the other position.

By configuring the welding system 70 in this manner, the welding operator can easily call up the desired welding conditions and set them in the welding power source 2 without making a mistake while welding. In particular, even if the welding operator is wearing a protective mask or gloves, the welding conditions can be easily changed during welding and set in the welding power source 2 simply by performing the simple task of changing the position of the remote control device 1. This allows welding of the workpiece 60 to continue seamlessly.

In addition, according to this embodiment, the welding conditions and the attitude of the remote control device 1 are associated and stored in the memory unit 22 of the welding power source 2, so after changing the welding conditions, it is easy to return to the conditions before the change simply by changing the attitude of the remote control device 1.

The remote control device 1 further includes an operation unit 11. After one welding condition is changed to another welding condition, the operating conditions of the welding power source 2 are fixed to the other welding condition by operating the operation unit 11.

In this way, even if the welding operator unintentionally changes the position of the remote control device 1 and as a result the welding conditions set in the welding power source 2 change, the actual operating conditions of the welding power source 2 will not change unless the welding operator intentionally operates the operation unit 11.

By preventing unintended changes to welding conditions in this way, desired welding can be performed while ensuring the safety of the welding operator.

The remote control device 1 may further include a notification unit. In this case, when the position of the remote control device 1 is changed from one position to another position, the notification unit notifies the welding operator that the operating conditions of the welding power source 2 are changed from one welding condition to another welding condition.

This allows the welding operator to be aware that the welding conditions will be changed even if he or she is wearing protective gear or gloves, and prevents forgetting to change the welding conditions.

The welding method according to this embodiment uses a welding system 70 and includes the steps shown below.

This welding method includes at least a first step (step S2 in FIG. 3) of setting one welding condition in the welding power source 2, a second step (step S3 in FIG. 3) of operating the welding power source 2 under the one welding condition and welding the workpiece 60, and a third step (step S5 in FIG. 3) of changing the position of the remote control device 1 from one position to another position to change the operating condition of the welding power source 2 from one welding condition to another welding condition.

This welding method also includes a fifth step (step S7 in FIG. 3) in which, after the third step, the welding power source 2 is operated under other welding conditions to weld the workpiece 60.

In this way, the welding operator can easily call up the desired welding conditions and set them in the welding power source 2 without making a mistake during welding. In particular, even if the welding operator is wearing a protective mask or gloves, the welding conditions can be easily changed during welding and set in the welding power source 2 simply by performing the simple task of changing the position of the remote control device 1. This allows welding to continue seamlessly on the workpiece 60.

It is also preferable to further include a fourth step (step S6 in FIG. 3) of determining the operating conditions of the welding power source 2 to be other welding conditions after the third step and before the fifth step.

In this way, even if the welding operator unintentionally changes the position of the remote control device 1 and as a result the welding conditions set in the welding power source 2 change, the actual operating conditions of the welding power source 2 will not change unless the welding operator intentionally operates the operation unit 11.

By preventing unintended changes to welding conditions in this way, desired welding can be performed while ensuring the safety of the welding operator.

Other Embodiments
In the embodiment, the welding system 70 that performs consumable electrode type arc welding using a welding wire has been described, but the present invention is not particularly limited to this. For example, the welding system 70 may be a non-consumable electrode type arc welding in which a non-consumable electrode is held by the torch 4 and an arc is generated between the non-consumable electrode and the workpiece 60.

Furthermore, it goes without saying that the welding system 70 and the welding method using the same disclosed herein can be applied to welding systems that perform so-called manual welding, in which a welding operator holds the remote control device 1 and the torch 4 in each hand, regardless of whether the system is a consumable electrode system or a non-consumable electrode system.

The welding system disclosed herein allows the welding operator to easily recall the desired welding conditions and set them in the welding power source without making mistakes while welding, making it useful in situations such as when performing seamless welding on a workpiece.

Reference Signs List 1 Remote control device 2 Welding power source 3 Welding feeder 4 Torch 11 Operation unit 12 Memory unit 13 Measurement unit 14 Control unit 15 Display unit 16 Wireless communication unit 17 Antenna 21 Operation unit 22 Memory unit 24 Control unit 26 Wireless communication unit 27 Antenna 28 Output unit 51, 52 Power cable 60 Workpiece 70 Welding system

Claims (5)

A welding system including at least a welding power source, a remote control device configured to be able to communicate with the welding power source, and a torch electrically connected to the welding power source,
The remote control device has at least a measurement unit that measures an acceleration applied to the remote control device,
a control unit that determines an attitude of the remote control device with respect to a gravity direction is provided in at least one of the welding power source and the remote control device,
different postures of the remote control device and different welding conditions of the welding power source are stored in association with each other,
A welding system characterized in that, when the position of the remote control device is changed from one position to another position, the welding conditions read out to the welding power source are changed from one welding condition associated with the one position to another welding condition associated with the other position. 2. The welding system of claim 1,
The remote control device further includes an operation unit,
After the one welding condition is changed to the other welding condition, the operation unit is operated,
A welding system, characterized in that the operating conditions of the welding power source are determined to be the other welding conditions. 2. The welding system of claim 1,
The remote control device further includes a notification unit,
When the attitude of the remote control device is changed from the one attitude to the other attitude,
The welding system according to claim 1, wherein the notification unit notifies a welding operator that the operating condition of the welding power source will be changed from the one welding condition to the other welding condition. A welding method using the welding system according to claim 1,
a first step of setting the one welding condition in the welding power source;
a second step of operating the welding power source under the one welding condition to weld a workpiece;
a third step of changing an operating condition of the welding power source from the one welding condition to the other welding condition by changing a posture of the remote control device from the one posture to the other posture;
and a fifth step of operating the welding power source under the other welding condition and welding the workpiece after the third step is performed. The welding method according to claim 4,
After the third step is performed and before the fifth step is performed,
The welding method further comprises a fourth step of determining operating conditions of the welding power source to be the other welding conditions.