KR20140121882A - Welding apparatus with automated welding wire retraction - Google Patents

Abstract

A method of providing a welding apparatus (100) configured to supply a welding wire (136) to a welding gun (130) and a welding apparatus for performing the method are disclosed. The welding gun 130 includes a trigger 134 and an opening in which the welding wire 136 extends when the trigger 134 is actuated. The method also includes providing a computer having a user interface 126 that includes an automatic wire retraction program, the program including at least one of a welding arc current, a welding wire size, a welding wire speed, and a burnback time And dynamically adjusts the degree of retraction of the welding wire on the basis of the following equation. The program monitors the weld gun 130 and determines when the trigger 134 is disabled.

Description

[0001] WELDING APPARATUS WITH AUTOMATED WELDING WIRE RETRACTION [0002]

This application is a continuation-in-part of U.S. Patent Application No. 13 / 370,652, filed February 10, 2012, which is a continuation-in-part of patent application No. 12 / 967,667, filed December 14, 2010, These patent applications are hereby incorporated by reference in their entirety.

The present invention relates to an automated wire retraction method for a welding apparatus. The present invention also relates to modifying or changing the welding apparatus to include an automated wire retraction method.

The welding device is configured to be operated by a person other than the welder. Typically, such a welding apparatus includes a welding wire feeder that advances the welding wire to the welding gun when the welder actuates the welding gun trigger (e.g., by pulling the trigger or by pressing the foot pedal). After welding is completed, the point ends of the welding wire may extend from the tip of the welding gun to expose the welder and others to potentially unsafe conditions.

It is an object of the present invention to provide an apparatus and a method for solving these shortcomings in relation to the above-mentioned problems and disadvantages present in a welding apparatus.

The above-mentioned problem is solved by a method for improving the safety of the welding operation according to claim 13 by the method according to claim 6 by the automatic wire retraction method according to claim 1, by a welding operation method according to claim 14, 15, 16 and 17, respectively. Other embodiments of the invention are subject of the dependent claims. In one aspect of the present invention, the disclosed automatic wire retraction method includes at least the following steps: a welding feeder configured to supply a welding power source, a welding wire, and a welder having an opening and a trigger, Providing a manual welding apparatus having a gun; Providing an automatic wire retraction program having a retraction delay time; Configuring the manual welding apparatus to include an automatic wire retraction program; Monitoring when a trigger is executed to extend the welding wire from the wire feeder to the opening and extending the welding wire from the opening of the welding gun; Determining a first time when the trigger is disabled; Determining when the first time is at least equal to a retraction delay time, wherein the trigger is deactivated during the first time; And at least partially retracting the welding wire into an opening of the welding gun during a retraction or retraction time, the at least partially retracting comprising the following parameters: welding arc current, welding wire size, welding wire speed, and dynamically at least partially retracts based on at least one of a burnback time. The first time, i.e., delay time, is typically a user-defined time based on past worker weld characteristics, and may be unique for each welding operation. The second time, i.e., the retraction time, is a dynamically adjusted value based on the characteristics of the employed welding operation. The degree of retraction is at least a partial retraction of the distance from the contact tip to the workpiece ("CTWD"), resulting in a complete retraction in the weld gun tip depending on the characteristics of the welding operation and the weld gun configuration, Or even partially extended beyond the welding gun tip, it retracts to a smaller distance than the CTWD during the welding operation.

Although the term "trigger" is used in the present patent application, it will be understood that it is intended to include a foot pedal operation, wherein the actuation mechanism is not physically provided to the weld gun body.

In another aspect of the present invention, there is provided a method of manufacturing a welding tool comprising the steps of providing at least the following steps: a manual welding apparatus configured to supply a welding wire to a welding gun, the welding gun having a trigger and an opening, And extending in said opening; Providing a computer with a user interface including an automatic wire retraction program; Monitoring the welding gun; Determining during the monitoring step whether the trigger is in an execution position or an inactive position; Performing a comparison using an automatic wire retraction program to determine if the trigger is in an inactive position and then to indicate when a first condition is met; At least partially retracting the welding wire after said comparison, wherein said at least partially retracting comprises dynamically welding based on at least one of the following parameters: welding arc current, welding wire size, welding wire speed, And at least partially retracting the wire.

In another aspect of the invention, a method of improving the safety of a welding operation using a welding torch employing a trigger to advance the welding wire is described, the method comprising the steps of: Pressing a trigger to advance the wire; Releasing the trigger to stop advancing the welding wire; Detecting if the trigger is in an unlocked position; Waiting for a first time; Comparing the first time with a preset waiting time; At least partially retracting the welding wire when the first time exceeds a preset waiting time; And continuing at least partially retracting for a second time, said step comprising: dynamically at least partially dynamically based on at least one of the following parameters: welding arc current, welding wire size, welding wire speed, Backward.

In another aspect of the invention, at least the following elements are present: welding power source; Welding wire feeder; A welding gun having means for controlling the welding wire feeder and in operable communication with the wire feeder; And a wire retraction program operatively communicating with the wire feeder, wherein the wire retraction program is configured to cause the wire feeder to transmit a signal to the wire feeder to cause the means for controlling the wire feeder to stop feeding the wire Detection means for detecting when a communication is made; And a comparator for measuring an elapsed time between a signal for interrupting the supply of wire and a current time, the program comprising the steps of: determining that the elapsed time has exceeded a predetermined time, And at least partially retracting the wire dynamically communicates a signal to the wire feeder based on at least one of the following parameters: a welding arc current, a welding wire size, a welding wire speed, At least partially.

In another aspect of the present invention, the described welding apparatus comprises at least the following components: welding power source; Wire feeder; A welding gun operatively communicating with the wire feeder and having means for controlling the wire feeder; And a wire retraction program operatively communicating with the wire feeder, wherein the wire retraction program is operable to detect when the means for controlling the wire feeder is in communication of a signal to the wire to interrupt the supply of the wire Wherein the program operably communicates the signal to the wire feeder to at least partially retract the wire after a signal to the wire feeder to interrupt the supply of the wire after a predetermined set time, At least partially retracting the wire is at least partially retracting the wire dynamically based on at least one of the following parameters: a welding arc current, a welding wire size, a welding wire speed and a backing time.

Although a weld stop delay is usually preferred, it is not always fundamental, and the present invention uses a welding torch that employs a trigger to advance the welding wire and uses the following steps to advance the welding wire to initiate the welding operation Pressing the trigger; Releasing the trigger to stop advancing the welding wire; Detecting that the trigger is in the released position; At least partially retracting the welding wire after at least partially retracting the welding wire after detecting that the trigger is in the released position, wherein the step of at least partially retracting the wire comprises the following parameters: welding arc current, welding wire size, And at least partially retracting the wire dynamically based on at least one of a speed and a lightning time.

In combination with the foregoing, the following elements: welding power source; Wire feeder; A welding gun operatively communicating with the wire feeder and having means for controlling the wire feeder; And a wire retraction program operatively communicating with the wire feeder. Wherein the wire retraction program comprises detection means for detecting when the means for controlling the wire feeder communicates a signal to the wire feeder to stop feeding the wire, Operatively communicating a signal to the wire feeder to at least partially retract the wire after the wire is withdrawn and the wire retraction program is operable to communicate a signal to the wire feeder during at least one of the following parameters: a welding arc current, a weld wire size, Based on at least one, the distance the electrode protrudes is dynamically retracted relative to an approximate distance.

It is also within the scope of the present invention to provide a means for locating a welding device that does not have an automatic wire retraction program and for modifying the welding device so that an automatic wire retraction program is performed.

These and other objects of the present invention will become apparent upon reference to the accompanying drawings, the detailed description and the appended claims.

According to the present invention, it is possible to obtain a welding apparatus and a welding work method having an automated welding wire retraction means capable of solving the disadvantages and problems of the prior art.

The present invention may take the physical form in particular parts and arrangements of parts, the preferred embodiments of which are illustrated in the accompanying drawings, which are described in detail herein and form part of the specification.
1 is a perspective view of a welding apparatus.
2 is a side view of the weld gun of Fig.
3A to 3C are enlarged sectional views of the nozzle of FIG.
4A-4C are enlarged cross-sectional views of other nozzle embodiments.
Figures 5A-5C are enlarged cross-sectional views of yet another nozzle embodiment.
6A to 6C are side views of the tip of the welding gun of the modified example.
7 is a flow chart showing one embodiment of an automatic wire retraction method.
Figure 8 is a flow chart showing a method of changing the welding apparatus.
Figure 9 shows the contact tip distance ("CTWD") and electrode tip projection (ESO) for the workpiece.
10 is a graphical representation of the relationship between the wire feed rate (WFS-in / min), the contact tip distance ("CTWD") to the workpiece and the welding currents.

Best Mode for Carrying Out the Invention The best mode for carrying out the present invention will be described below to show the best mode known to the applicant at the time of the patent application of the present invention. The examples and figures are intended to illustrate, but not to limit, the invention, which is defined by the spirit and scope of the claims. As used herein, the following terms have the following meanings.

The term "contact tip distance to workpiece" or "CTWD" refers to the distance between the contact tip end 144a and the horizontal surface of the workpiece at the weld site,

The term "electrode projection" or "ESO" means, for example, the distance between the contact tip tip 144a and the distal tip of the electrode 136 as shown in FIG.

The term "proximity" means a measurement deviation from the horizontal plane of the contact tip end or nozzle end that is not greater than about 0.125 inches.

As shown in the drawing, the welding apparatus 100 includes a welding power source 102, a wire feeder 102, (104) and a gas supply source (106). The welding power source 102 includes a power cable 108, a control cable 110, and a power supply cable (not shown). The power cable 108 includes a clamp 112 connected to the workpiece and a ground wire and a power cable 114 configured to connect to the wire feeder 104. The control cable 110 may be configured to be connected to the wire feeder 104. In another embodiment, the control cable 110 may be configured wirelessly. It is understood that the welding power source 102, the power cable 108 and the control cable 110 may have any configuration suitable for power supply and welding control to the welding apparatus 100.

1, the gas pipe 116 and the regulator 118 are configured to connect the gas supply source 106 to the wire feeder 104. [ The gas source 106 may include an inert gas, an active gas, or a combination thereof, which may include argon, helium, carbon dioxide, argon and helium, argon and hydrogen, The present invention is not limited thereto. In another embodiment (not shown in the drawings), the welding apparatus 100 uses a welding wire coated with a material that forms a gas shield when burned, so that the gas source may not be necessary in all embodiments have. It should be understood that the gas source may be any gas or combination of gases configured to shield the weld from the atmosphere.

1, the wire feeder 104 includes a housing 120, a gear box 122, a wire spool assembly 124, and a user interface 126. As shown in FIG. The hose 128 extending from the gear box 122 is configured to connect to the weld gun 130. The housing 120 may be connected to the user interface 126 and the gear box 122. The control cable 110 and the power cable 114 extending from the welding power supply 102 and the gas pipe 116 extending from the gas supply source 106 are connected to the housing 120, the gear box 122, and the hose 128 As shown in FIG. The gear box 122 includes a plurality of rollers (not shown) for advancing and retracting a wire guide (not shown in the figure) controlling the path of the welding wire and a welding wire (not shown in the figure) . It should be understood that the wire feeder 104 may have any structure suitable for accommodating a gas source, a power source, and a weld control.

The hose 128 extending between the gear box 122 and the weld gun 130 operatively connects the welding wire and the weld tube, (if required), the gas line and the weld gun trigger switch connector. In another embodiment (not shown in the drawings), as described above, the hose 128 does not include a gas line. (Not shown), the hose 128 connects the weld gun 130 to at least one of the following: the welding power source 102, the wire feeder 104, and the gas source 106 As shown in FIG. The hose 128 may have any diameter and length configured to accommodate the welding wire, gas hose, and switch connector. The hose 128 is made of any material suitable for the welding environment. The hose 128 and the welding gun 130 may have any structure suitable for controlling the welding wire and the welding gas through the hose and supplying it to the welding gun.

In the illustrated embodiment of the welding apparatus 100, the user interface 126 includes a computer (or, alternatively, at least a CPU (not shown) having at least one processor ) And a set-up program. For example, the user interface 126 of the welding apparatus 100 may include a gear box 122 (not shown) on the wire feeder 104 to at least partially retract the exposed welding wire (not shown) ) Of the wire retracting program. The automatic wire retraction program is configured to prevent exposure of the welder to a potentially sharp end of the welding wire that may extend or protrude beyond the end or opening of the welding gun 130. The automatic wire retraction program can be password protected so that supervisors and other administrators can maintain control of the automatic wire retraction program.

In one embodiment of the invention described herein, the automatic wire retraction program compares the time delay between discontinuous uses of the welder of the welding apparatus 100 for a time greater than a preset first time , The automatic wire retraction program retracts the welding wire at least partially from the end or opening of the welding gun for a second time (inverse time) if it meets or exceeds a predetermined delay time. For example, the user interface 126 includes a first setting in which a retraction delay time is set and a second setting in which a wire retraction time is set. After these settings are completed, if the welder stops using the welding device for a time greater than or equal to the specified first setting time, the wire feeder will not be able to feed the welding wire for a second time (or distance as described below) .

In an alternate embodiment of the invention described herein, the automatic wire retraction program may be programmed to cause the welder to retract the welding gun 100 during a predetermined and fixed distance when the welding operator stops using the welding apparatus 100 more than the first delay time. To retract the welding wire from the end or opening. For example, the user interface 126 includes a first setting in which a retraction delay time is set and a second setting in which a retraction distance is set.

In another embodiment of the present invention described herein, if the welder has stopped using the welding device 100 more than the first time, the automatic wire retraction program will cause the sensor device (not shown) Is configured to at least partially retract the welding wire from the end or opening of the welding gun until it indicates that there is an end of the welding wire in the safety zone (not shown) in the gun (130). For example, the automatic wire retraction program retracts the welding wire until the sensor is actuated and the sensor indicates that the end of the welding wire is contained in a nozzle, a tip (not shown) or these nozzles and tips. An automatic wire retraction method for a welding apparatus will be described further below. The user interface and automatic wire retraction program allow the end of the welding wire of the welding apparatus to be at least partially retracted into a portion of the welding gun, e.g., into the tip and nozzle, in any manner so that the welding operator is not exposed to the potentially sharp welding wire .

As shown in FIG. 2, the hose 128 is configured to be connected to the welding gun 130 proximate the welding gun handle 132. The trigger 134 on the handle 132 is connected to the wire feeder gear 132 via the hose 128 and the handle 132 and also along the neck 138 and nozzle 140 To advance the welding wire 136. The nozzle 140 is configured to be removably attached to the neck 138. Trigger 134 may also be configured to control the weld shielding gas. For example, the welding wire 136 may extend from the nozzle 140 and may be configured so that when the welding operator operates the trigger 134 (i.e., when the trigger is fully or at least partially The welding shielding gas will surround the welding wire. In another embodiment (not shown), the neck 138 may have a longer or shorter length and may be bent at an angle different from that shown in FIG. The welding gun 130 may have any configuration suitable for the welding operator to control the advancement of the welding wire and the supply of welding shielding gas.

As shown in Figure 2, the nozzle 140 includes an insulating boss 142 in one embodiment, which prevents heating and allows the nozzle 140, And at least one of the welding gun handle 132 and the welding gun handle 132. Within the nozzle 140, the tip 144 is configured to removably attach to the neck 138. The tip 144 also allows the welding gas to be discharged from the gas passage 146 to guide the welding wire 136 along the center of the nozzle 140 and to shield the welding wire 136 from the environment . In another embodiment (not shown), the welding gun includes a handle 132, a trigger 134, a neck 138, a tip 144, and a gas passage 146. In this configuration, the welding gun 130 does not include the nozzle 140. It should be understood that the nozzle 140 may have any configuration suitable for the welding worker to control the supply of welding wire and welding shielding gas.

FIGS. 3A-3C are enlarged cross-sectional views of the nozzle 140 of FIG. 2 wherein the tip 144 is configured to lie within the end 140a of the nozzle 140. FIG. A series of Figures 3A-3C show examples of how the welding device 100 is configured to operate when using the automatic wire retraction program. For purposes of this illustration, FIG. 3A shows a cross-section of a nozzle 140 for an initial welding condition before the welding operator uses the welding apparatus 100. 3a shows a nozzle 140 having a welding wire 136 extending from a tip 144 and the welding wire 136 and tip 144 are positioned completely within the end 140a of the nozzle 140 do. 3B shows a cross section of the nozzle following the welding worker using the welding apparatus 100. Fig. 3B, the welding wire 136 extends beyond the end 140a of the nozzle 140, and the welding operator is potentially exposed at the end of the welding wire 136. As shown in Fig. 3C, the welding apparatus 100 can move the end 140a of the nozzle 140 when the welding operator stops the welding for a specified period of time, as shown in FIG. 3C, by executing the wire retraction program through the user interface 126. [ So as to automatically retreat the end of the welding wire 136. [ For example, if the welder stops welding for 20 seconds, the automatic wire retraction program retracts the welding wire to prevent exposure to the welder. In other embodiments (not shown in the drawings), the nozzle and tip may be longer or shorter than those shown in Figures 3A-3C. It is understood that the welding apparatus 100 may be constructed using an automatic wire retraction program such that the welding wire is retracted at least into the end 140a of the nozzle 140 when the welding operator stops welding for a specified amount of time . The foregoing times are for illustrative purposes only and longer or shorter time intervals are within the scope of the present invention. Although a complete retraction of the welding wire 136 is shown, the present invention also includes embodiments where the welding wire is only partially retracted from the extended state shown in FIG. 3b. In this aspect of the invention, the welding wire may still extend beyond the end 140a, but not extend to that illustrated in Figure 3b.

4A-4C are enlarged cross-sectional views of the nozzle 140 of FIG. 2, in which the tip 144 is configured to extend past the end of the nozzle 140. FIG. Similar to Figs. 3A-3C, a series of Figs. 4A-4C illustrate examples of how the welding apparatus 100 is configured to operate when using an automatic wire retraction program. Also for purposes of this illustration, FIG. 4A shows a cross-section of a nozzle 140 for an initial welding condition before the welding operator uses the welding apparatus 100. FIG. Figure 4a shows nozzle 140 and tip 144 where the welding wire does not extend from tip 144 and tip 144 extends beyond end 140a of nozzle 140. 4B shows a cross section of the nozzle following the welding worker using the welding apparatus 100. Fig. 4b, the welding wire 136 extends from the end of the tip 144 to permit the welding operator to be exposed to the end of the welding wire 136. [ 4C, when the welding operator stops the welding for a certain period of time by executing the automatic wire retraction program via the user interface 126, the welding apparatus 100 can move the welding wire (not shown) in the end of the tip 144 136 to automatically retreat. In other embodiments (not shown), the tip may be longer or shorter than that shown in Figures 4a-4c. In the same manner as described in Figures 3A-3C, the overall retraction of the welding wire 136 is not mandatory and may consist of only at least partial retraction from that described in Figure 4B.

5A-5C are enlarged cross-sectional views of another embodiment of the nozzle 140 of FIG. 2 wherein the tip 144 is configured to lie within the end 140a of the nozzle 140. FIG. In addition, the nozzle includes at least one sensor 148 configured to indicate the position of the welding wire 136. The at least one sensor may comprise at least one of the following proximity sensors: mechanical sensors, electrical sensors, optical sensors, laser sensors, ultrasonic sensors, and the like. A series of Figures 5A-5C show examples of how a welding device is configured to operate when using an automatic wire retraction program with at least one sensor. 5A shows a cross section of the nozzle 140 for an initial welding condition before the welding operator uses the welding apparatus 100. FIG. Figure 5a shows nozzle 140 and tip 144 where the welding wire does not extend from tip 144 and at least one sensor 148 does not sense welding wire 136. Fig. 5B shows the nozzle cross section following the welding worker using the welding apparatus 100. Fig. 5b, the welding wire 136 extends beyond the end of the nozzle 140 and the tip 144 to potentially expose the welder to the end of the welding wire 136. As shown in FIG. The welding apparatus 100 automatically positions the end of the welding wire 136 in the end portion 140a of the nozzle 140 by executing an automatic wire retraction program through the user interface 126 Backward. The welding wire is retracted until at least one sensor 148 indicating that the end of the welding wire is in the nozzle 140 or the tip 144 is activated by the welding wire, as shown in Fig. 5C. In other embodiments (not shown in the drawings), the tip may be longer or shorter than that shown in Figures 5A-5C. In another embodiment (not shown in the figures), the number of sensors 148 may be more or less than the number shown in Figures 5A-5C. Consistent with the explanations with respect to the previous figures, although a global retraction is not essential, an embodiment of the present invention requires at least partial retraction in the generally extended position shown in Fig. 5b.

Figures 6A-6C are side views of a tip 144 of a welding gun of the variant in which the welding gun (not shown) does not include a nozzle so that the entire tip 144 is exposed. 6A-6C illustrate examples of how the welding apparatus 100 is configured to operate when using the automatic wire retraction program. 6A shows a side view of the tip 144 for the initial welding conditions before the welding operator uses the welding apparatus 100. FIG. Figure 6a shows the case where the welding wire does not extend from the exposed tip 144. 6B shows a side view of the tip 144 after the welding operator has used the welding apparatus 100. FIG. 6b, a welding wire 136 extends from the end of the tip 144 to potentially expose the welding operator to the end of the welding wire 136. As shown in Fig. 6C, the welding device 100 may be welded to the end of the tip 144 when the welding operator stops welding for a specified time, by executing an automatic wire retraction program via the user interface 126. [ And to automatically retract the end of the wire 136. In other embodiments (not shown in the drawings), the tip may be longer or shorter than that shown in Figures 6a-6c to match the above.

7 is a flow chart illustrating one embodiment of an automatic wire retraction method 700 for a welding apparatus 100. As shown in FIG. As shown in Fig. 7, the welding apparatus is configured to be energized at step 702. Fig. At step 704, the computer with the automatic wire retraction program determines whether the user attempts to access the setup menu via the user interface or the computer. If the user attempts to access the setup menu at step 704, the computer determines at step 706 whether the setup menu is locked. If the setup menu is in the locked state in the selection step 706, the computer determines whether the user enters the correct password in step 708. [ If the setup menu is in the locked state and the user does not enter the correct password, the computer will block the connection to the setup parameters and allow the user to go back to the previous user interface selection step 710. If the setup menu is in the locked state and the user enters the correct password, the computer allows user access to the setup parameters to execute or stop the automatic wire retraction program of step 712. After the user has enabled or disabled the automatic wire retraction program and its associated parameters, the computer returns the user to the previous user interface at select step 714. [ For example, the user can adjust at least one of the following parameters: retraction time delay, retraction time, retraction distance, and proximity sensor parameters.

If the user does not attempt to connect to the setup menu at step 704, the computer determines whether the weld gun trigger is executable at step 716. [ If the weld gun trigger is not executable and power is applied to the welding apparatus, the computer waits until the weld gun trigger is enabled, or until the user attempts to contact the setup menu at step 718. If the weld gun trigger is viable at step 716, the wire feeder is activated and the welding power source supplies power at step 720. [ In step 722, the computer determines whether the weld gun trigger is disabled. If the weld gun trigger has not been disabled, the computer monitors the weld gun trigger at step 724. If the weld gun trigger is disabled in step 722, the computer determines in step 726 whether the weld arc is off. If not, the computer monitors the welding arc in step 728. If not,

If the weld arc is turned off in step 726, the computer tracks the latency delay and, in step 730, determines whether the latency delay is greater than the retraction delay time set in the user interface. For example, the retraction delay time may be any time greater than zero. If the wait time delay is less than the retraction delay time set in the user interface, the computer continuously monitors the wait time delay. If the latency delay is at least equal to the retraction delay time set in the user interface, the computer checks in step 732 to see if the weld gun trigger is executable. If in step 732 the weld gun trigger is feasible, the wire feeder will start operating and the welding power source will supply power in step 720. If the weld gun trigger is not executable at step 732 and the wait time delay is at least equal to the retraction delay time set at the user interface, then the automatic wire retraction program retracts the welding wire based on the user interface parameters at step 734. [ For example, the welding wire may be retracted for a specified distance or set time. At step 736, the computer determines whether the weld gun trigger is executable. If the weld gun trigger is executable in step 736, then in step 720, the wire feeder is activated and the welding power source provides power. If the weld gun trigger is not feasible at step 736, then at step 738 the computer returns to method initial at step 704. [ It is important in step 732 to be able to activate the trigger to restart the welding process during the retraction delay time, as if a weld gun trigger were employed. It is not necessary to wait for the entire retraction delay period before restarting the weld.

In another embodiment of the method of the present invention, the computer monitors the gearbox drive motor on the wire feeder for excessive current or torque, wherein the excessive current or torque represents a problem with the automatic wire retraction method. In any case, the welding apparatus 100 using the automatic wire retraction method 700 is configured such that when the welding operator stops welding for a specified period of time, the welding wire is moved at least to the end 140a of the nozzle 140, 144). ≪ / RTI >

In another embodiment (not shown) of the automatic wire retraction method 700 for the welding apparatus 100, the method 700 includes at least one of the following method steps. When the weld gun trigger is enabled, the wire feeder commences operation and the welding power source supplies power. The computer is configured to determine if the weld gun trigger is disabled. If the weld gun trigger is not disabled, the computer monitors the weld gun trigger. Alternatively, if the weld gun trigger is disabled, the computer determines whether the welding arc is off. If the welding arc is not turned off, the computer monitors the welding arc. Once the welding arc is turned off, the computer is configured to track the latency delay and determine if the latency delay is greater than a retraction delay time set at the user interface. If the wait time delay is less than the retraction delay time set in the user interface, the computer continues to count the wait time delay. If the latency delay is at least equal to the retraction delay time set in the user interface, the computer checks to confirm that the weld gun trigger is executable. If the weld gun trigger is operable, the wire feeder is activated and the welding power source supplies power. If the weld gun trigger is not enabled and the wait time delay is at least equal to the retraction delay time set in the user interface, the automatic wire retraction program retracts the welding wire. With respect to the possibility of restarting the welding operation during the retraction delay time period, the same applies as described above.

Figure 8 is a flow chart illustrating one embodiment of an automatic wire retraction method for altering or retrofitting a welding apparatus. As shown in Fig. 8, at step 802, a welding apparatus without an automatic wire retraction program is located. At step 804, the already manufactured or sold welding device is modified or changed to an automatic wire retraction program. For example, at least one of the following: software programs, hardware, relays, printed circuit boards, wire harnesses, user interfaces, etc., are added or modified in the welding apparatus.

A user interface 126 or computer, which may include a computer with an automatic wire retraction program, represents one possible hardware configuration for supporting the above-described apparatus and method including the method 700, 800. [ In order to provide additional context for various aspects of the present invention, the following description is intended to provide a general, brief description of a suitable computer environment in which the various aspects of the present invention may be practiced. Those skilled in the art will appreciate that the present invention may also be implemented as a combination of hardware and software and / or in combination with other program modules. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks or implement a particular abstract data type.

Moreover, those skilled in the art will appreciate that the methods of the present invention may be practiced with other computer systems, including single-processor or multiprocessor computer devices, minicomputers, mainframe computers, as well as personal computers, portable computer devices, Products, and the like, each of which may be operatively connected to one or more related devices. The aspects described above for the present invention may also be implemented in a distributed computing environment where certain tasks may be performed by remote processing devices linked through a communications network. In a distributed computer environment, program modules may be located in both the local memory storage device and the remote memory storage device.

The user interface 126 associated with the automatic wire retraction program may utilize an exemplary environment for implementing various aspects of the present invention, including a computer including a processing unit, a system memory, and a system bus. The system bus connects system components, including but not limited to system memory, to a processing unit. The processing unit may be any of a number of commercially available processors. Dual microprocessor architectures and other multi-processor architectures may also be employed as processing units.

The system bus may be any of several types of bus structures including a local bus, a peripheral bus, a memory bus, or a memory controller using any of a variety of commercially available bus architectures. The system memory may include a ROM and a RAM. A basic input / output system (BIOS), containing the basic routines that help to convey information between different elements of the computer, such as during startup, is stored in the ROM.

A user interface 126 or computer, which may include a computer having an automatic wire retraction program, may be configured to read, for example, a hard disk drive, a magnetic disk drive, and, for example, a CD-ROM disk for writing to or reading from a removable disk Or an optical disc drive for writing to or reading from another optical medium. The user interface 126 or computer, which may include a computer capable of including an automatic wire retraction program, may include at least some of the various types of computer readable media. The computer-readable medium may be any available medium that can be connected by a computer. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile removable media and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. The computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, which may be used to store the required information and may be accessed by the user interface 126, CD- A multipurpose disk (DVD), or other magnetic storage device or any other medium.

Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal, such as a carrier wave or other transmission device, and includes any information delivery media. The term "modulated data signal" means a signal having one or more of the characteristics altered or set as a method for encoding information into a signal. By way of example only, and not limitation, communication media includes wired media such as a wired network, direct-wired connection, and wireless media such as acoustic, RF, infrared media or other wireless media. Combinations of any of the foregoing may also be included within the scope of computer readable media.

Many program modules include an operating system, one or more application programs, other program modules, and program data, and may be stored in a driver and a RAM. The user interface 126 or the operating system of the computer may be any of a number of commercially available operating systems.

In addition, a user may enter commands and information into a computer device via a pointing device such as a keyboard and a mouse. Other input devices may include a microphone, an IR remote control, a trackball, a pen input device, a joystick, a game pad, a digitizing tablet, a satellite antenna, a scanner, and the like. These input devices and other input devices are often connected to the processing unit via a serial port interface connected to the system bus, but may be connected to the processing unit via a parallel port, a game port, a universal serial bus ("USB"), an IR interface, It may be connected by another interface. Monitors and other types of display devices may also be connected to the system bus through an interface, such as a video adapter. Visual output can also be achieved through remote display network protocols such as Remote Desktop Protocol, VNC, X-Window System, and the like. In addition to visual output, the computer typically includes other peripheral output devices such as speakers, printers, and the like.

The display may be employed in the user interface 126 to provide electronically received data from the processing unit. For example, the display may be an LCD monitor, a plasma monitor, a CRT monitor, or the like, which electronically provides data. Alternatively or additionally, the display may provide the received data in hard copy format, such as a printer, fax, plotter, or the like. The display may provide the data in any color and may receive data from the user interface 126 via wireless or hardwire protocols and / or standards.

The computer may operate in a networked environment using logical and / or physical connections to one or more remote computers, such as a remote computer. The remote computer may be a workstation, a server computer, a router, a personal computer, a microprocessor-based entertainment device, a peer device or other common network node, and typically includes any or all of the elements described in connection with the computer Includes a number of elements. The logical connection includes a local area network (LAN) and a wide area network (WAN). Such a network environment may be a corporate-wide computer network, an intranet, and the Internet common in offices.

When used in a LAN network environment, the computer is connected to the local network through a network interface or adapter. When used in a WAN networking environment, a computer typically has a modem, or other means of connecting to a communication server on a LAN, or forming a communication over the WAN, such as the Internet. In a networked environment, program modules described in connection with the computer, or portions thereof, may be stored in a remote memory storage device. It will be appreciated that the network connections described herein are exemplary and that other means of forming a communication link between the computers may be used.

As described above, the retraction time or retraction distance is fixed based on what the user typically enters into the software retraction program via the user interface 126. [ However, while this is also improved over the prior art, dynamic retraction time (or dynamic retraction distance) based on wire size and / or wire speed and / or average current provides an excellent solution. As in the prior art solution, the retraction time and / or retraction distance does not require the welding wire tip to be fully retracted, but can be retracted at least some distance from the fully extended distance when the welding operation is stopped.

As shown in Fig. 10, the fixed retraction time and / or the fixed retraction distance is not intended to change the contact distance change to the workpiece. Considering at least one of the following items to determine the size of the wire projecting from the opening of the welding gun: arc current, wire size, wire speed, rebound time and / or process tip, etc. (or at least one combination of the above parameters) The solution provides an advantage that can not be achieved in a static solution. When the welding operation is stopped, regardless of the wire projecting position ESO, the wire preferably retracts close to the welding gun tip or to a point located between the tip and the nozzle. If the wire is retracted too far, the next weld may be delayed until the contact distance with the appropriate workpiece is achieved. If the wire is not sufficiently retracted, the wire will protrude from the gun assembly by a distance such that it does not achieve all of the safe aspects of the present invention. Figure 10 also shows the interaction between the workpiece contact distance and the welding current for a given diameter of welding wire at various wire feed rates. This relationship can be defined for any combination of variables taking into account the effect of the weld material differences. The degree of retraction can be used by interpolation from mathematical equations or data table values based on the curves shown in FIG. 10, or by combining them.

Using Figure 10 as a non-limiting example, it is assumed that the user welds at an average welding current of 200 amps, welding wire feed rate of 300 in / min, using the appropriate welding procedure, So that a retraction distance of between about 1 and 1.125 inches would be appropriate as a retraction distance and an electrode protrusion of about 0.125 inches would be sufficient to ensure that the welding operation is complete and that the It is not enough to infiltrate the worker's work clothes at the time of subsequent contact of the welder.

While the invention has been described with reference to specific embodiments, it will be understood that various changes may be made and equivalents may be substituted therein by those skilled in the art without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the present invention not be limited to the particular embodiment described, but that it is intended to cover all embodiments falling within the scope of the appended claims.

100: welding device 148: sensor
102: Power 700: Method
104: wire feeder 702:
106: gas source 704:
108: power cable 706: step
110: control cable 708: step
112: clamp 710: step
114: power cable 712: step
116: Gas pipe 714:
118: regulator 716: step
120: Housing 718:
122: gear box 720: step
124: spool assembly 722:
126: User interface 724:
128: Hose 726:
130: welding gun 728:
132: welding gun handle 730: step
134: Trigger 732:
136: Welding wire 734:
138: Neck 736:
140: nozzle 738:
140a: End 800: Method
142: boss 802: step
144: Tip 804: Step
146: gas passage

Claims (17)

A welding gun (130) having a welding power supply (102), a wire feeder (104) configured to supply a welding wire (136), and an opening and a trigger (134) (100) having a welding gun in which a welding wire is extended from the welding tool (100);
Providing an automatic wire retraction program having a retraction delay time;
Configuring the manual welding apparatus (100) to include an automatic wire retraction program;
Monitoring when the trigger 134 is executed to extend the welding wire 136 from the wire feeder 136 to the opening and extending the welding wire 136 from the opening of the welding gun 130;
Determining a first time when the trigger (134) is disabled;
Determining when the first time is at least equal to a retraction delay time, wherein during the first time the trigger (134) is deactivated; And
At least partially retracting the welding wire (136) into the opening of the welding gun (130) during a retraction or retraction time, said step comprising the following parameters: welding arc current, welding wire size, And at least partially retracting the welding wire dynamically based on at least one of a burnback time
Wherein the automatic wire retraction method comprises: The method according to claim 1,
The step of retracting the welding wire (136) into the opening of the weld gun (130) is configured to retract during a retraction time or retraction distance, the retraction time being dynamically adjusted in an automatic wire retraction program and / Wherein the distance is dynamically adjusted in an automatic wire retraction program. The method of claim 1 or 2, wherein after at least partially retracting into an opening of a weld gun (130) comprising a nozzle (140) with a nozzle end (140a) and a tip (144) The welding wire 136 does not extend beyond the nozzle end 140a and / or the welding wire 136 retracts into the nozzle end 140a and / or the welding wire 136 contacts the nozzle end 140a, And / or the welding wire 136 is retracted into the tip 144, and / or the welding wire 136 extends beyond the tip 144, and / But is less than the contact distance to the wire during welding. The method of any one of the preceding claims, wherein after the step of at least partially retracting into the opening of the welding gun (130) including the tip (144), the welding wire (136) And wherein the second wire is not extended beyond the first wire. 5. The method according to any one of claims 1 to 4,
Sensing at least one parameter by at least one sensor (148) configured to indicate an end of the welding wire
Wherein the step of at least partially retracting at least one sensor parameter is configured to determine when the retraction phase is completed. Providing a manual welding device (100) configured to supply a welding wire (136) to a welding gun (130), the welding gun (130) having a trigger (134) Extends through the opening when the trigger (134) is activated;
Providing a computer with a user interface (126) including an automatic wire retraction program;
Monitoring the welding gun 130;
Determining during the monitoring step whether the trigger 134 is enabled or disabled;
Constructing and using an automatic wire retraction program to determine when the trigger (134) is deactivated and then when a first condition is met;
At least partially retracting the welding wire 136 after the comparison, wherein the step is based on at least one of the following parameters: a welding arc current, a welding wire size, a welding wire feed rate, and a burnback time And dynamically at least partially retracts the wire (130)
≪ / RTI > 7. The method of claim 6, wherein the first condition is a dynamically adjusted retraction delay time. 8. The method according to claim 6 or 7,
Determining a first time when the trigger 134 is suspended,
Determining when the first time is at least equal to the retraction delay time
≪ / RTI > 9. The method according to any one of claims 6 to 8,
Configuring the user interface 126 to include at least one sensor 148, a dynamic sensor parameter for the at least one sensor 148, and a retraction delay time
, Wherein the at least one sensor (148) is configured to indicate an end of the welding wire (136), and wherein retracting the wire at least partially with the sensor parameter is indicative of when to retract the retraction phase ≪ / RTI > 10. A method according to any one of claims 6 to 9, wherein the opening of the welding gun (130) comprises a nozzle (140) having a nozzle end (140a) and a tip (144) Does not extend past the nozzle end (140a) until at least the end of the partially retracting step. 11. A method according to any one of claims 6 to 10, wherein the opening of the welding gun (130) comprises a tip (144) and the welding wire (136) 144). ≪ / RTI > 12. A method according to any one of claims 6 to 11, wherein the opening of the welding gun (130) comprises a tip (144) and the welding wire (136) is at least partially retracted Wherein the step of withdrawing is a distance less than the tip contact distance for the projected distance or the workpiece. 1. A method for improving the safety of a welding operation using a welding torch employing a trigger (134) for advancing a welding wire (136)
Pressing the trigger (134) to advance the welding wire (136) to initiate a welding operation;
Releasing the trigger (134) to interrupt the advancement of the welding wire (136);
Detecting if the trigger (134) is in the released position;
Waiting for a first time;
Comparing the first time with a preset waiting time;
At least partially retracting the welding wire (136) when the first time exceeds a predetermined waiting time; And
Continuing said step of at least partially retracting for a second time, said step comprising: dynamically at least partially dynamically based on at least one of the following parameters: welding arc current, welding wire size, welding wire speed, Step to retract
≪ / RTI > A welding operation method using a welding torch employing a trigger (134) for advancing a welding wire (136)
Pressing the trigger (134) to advance the welding wire (136) to initiate a welding operation;
Releasing the trigger (134) to interrupt the advancement of the welding wire;
Detecting that the trigger (134) is in the released position; And
At least partially retracting the welding wire (136) after detecting that the trigger (134) is in the unlocked position, said step comprising the following parameters: welding arc current, welding wire size, And at least partially retracting the welding wire (136) dynamically based on at least one of the back-
. Welding power source 102;
A wire feeder 104;
A welding gun (130) having means for controlling the wire feeder (104) and in operable communication with the wire feeder (104); And
A wire retracting program operatively communicating with the wire feeder (104)
Wherein the wire retraction program comprises:
Detection means for determining when said means for controlling said wire feeder has communicated a signal to said wire feeder (104) to stop feeding said wire (136); And
A comparator for measuring an elapsed time between the signal for stopping the supply of the wire and the current time;
The program operably communicating a signal to the wire feeder 104 to cause the comparator to at least partially retract the wire 136 after determining that the elapsed time has exceeded a predetermined time, Wherein at least partially retracting the wire dynamically retracts the wire at least partially based on at least one of the following parameters: a welding arc current, a welding wire size, a welding wire feed rate, Device. Welding power source 102;
A wire feeder 104;
A welding gun (130) in operable communication with the wire feeder (104) and having means for controlling the wire feeder (104); And
A wire retracting program operatively communicating with the wire feeder (104)
Wherein the wire retraction program comprises detection means for determining when the means for controlling the wire feeder 104 is to communicate a signal to the wire feeder 104 to interrupt the supply of the wire 136 , The program operably communicating a signal to the wire feeder (104) to at least partially retract the wire (136) after the wire feeder (104) stops feeding the wire, Wherein the wire withdrawal program dynamically retracts the distance the electrode projects, based on at least one of the following parameters: the welding arc current, the welding wire size, the welding wire feed rate, and the elongation time, to an approximate distance. Welding power source 102;
A wire feeder 104;
A welding gun (130) operatively communicating with the wire feeder (104) and having means for controlling the wire feeder (104); And
A wire retracting program operatively communicating with the wire feeder (104)
Wherein the wire retraction program comprises detection means for determining when the means for controlling the wire feeder 104 is to communicate a signal to the wire feeder 104 to stop feeding the wire 136 , The program causing the wire feeder (104) to signal a wire feeder (104) to at least partially retract the wire (136) after a signal to the wire feeder, causing the wire to stop feeding after a predetermined time Wherein said at least partially retracting dynamically retracts at least partially based on at least one of the following parameters: a welding arc current, a welding wire size, a welding wire feed rate, Device.

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