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WO2015145391A2 - Dispositif électrique et/ou électronique, en particulier machine à souder, doté d'un panneau de commande amovible - Google Patents

Dispositif électrique et/ou électronique, en particulier machine à souder, doté d'un panneau de commande amovible Download PDF

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Publication number
WO2015145391A2
WO2015145391A2 PCT/IB2015/052263 IB2015052263W WO2015145391A2 WO 2015145391 A2 WO2015145391 A2 WO 2015145391A2 IB 2015052263 W IB2015052263 W IB 2015052263W WO 2015145391 A2 WO2015145391 A2 WO 2015145391A2
Authority
WO
WIPO (PCT)
Prior art keywords
processing means
electronic
control panel
electric
input
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2015/052263
Other languages
English (en)
Other versions
WO2015145391A3 (fr
Inventor
Guglielmo De Rosa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Awelco Inc Production SpA
Original Assignee
Awelco Inc Production SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Awelco Inc Production SpA filed Critical Awelco Inc Production SpA
Publication of WO2015145391A2 publication Critical patent/WO2015145391A2/fr
Publication of WO2015145391A3 publication Critical patent/WO2015145391A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1006—Power supply
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1006—Power supply
    • B23K9/1043—Power supply characterised by the electric circuit
    • B23K9/1056—Power supply characterised by the electric circuit by using digital means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1006—Power supply
    • B23K9/1043—Power supply characterised by the electric circuit
    • B23K9/1056—Power supply characterised by the electric circuit by using digital means
    • B23K9/1062—Power supply characterised by the electric circuit by using digital means with computing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1087—Arc welding using remote control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/32—Accessories

Definitions

  • the present invention concerns an electric and/or electronic apparatus, in particular a welding machine, optionally an arc welding machine, with or without the addition of molten metal, provided with a removable control panel, optionally configured to be inserted into a housing of the apparatus, that allows to configure the operating parameters, to monitor the state of the components of the apparatus and to control the operation of the apparatus, as well as to provide an operator with information through speech and/or video messages concerning safety rules, technical rules for correct management of the parameters of the apparatus and rules for a good result in the apparatus operation, such as for instance a good result in welding;
  • the removable control panel may be connected to, optionally mounted on, a plurality of different apparatuses, whereby it is not specifically dedicated to an apparatus, and it is configured to recognise the type of apparatus on which it is mounted so as to be then capable to manage and adjust all the parameters of the apparatus on which it is mounted.
  • the invention allows in a reliable, versatile, effective, simple, and inexpensive way that is handy for the operator to configure, monitor and control a plurality of apparatuses, even of different types, optionally provided with a housing configured to house the removable control panel, which may be connected to the removable control panel.
  • the invention is shown mainly making reference to a welding machine.
  • any electrical or electronic apparatus e.g. battery chargers, safes with electronic control, burglar alarms, motor vehicle controlling electronic devices, machine tools such as for instance drills, circular saws and lawn mowers, electrical boxes, electromedical equipments, electronic apparatuses and devices for controlling civil or industrial electric traction vehicles
  • a household appliance e.g. washing machines, electric ovens, microwave ovens, dishwashers, refrigerators, cooking machines
  • SMAW Shided Metal Arc Welding
  • MMA Manton Metal Arc
  • GMAW Gas Metal Arc Welding
  • MIG Metal Inert Gas
  • MAG Metal Active Gas
  • TIG Tungsten Inert Gas
  • plasma welding the technique of which, similar to the TIG one, is also used for cutting metal.
  • a plurality of electrical and electronic welding machines are known, equipped with devices for detecting, controlling and managing the parameters relevant to the various welding processes.
  • Such machines are normally provided with a user interface that may be of variable complexity: in most simple cases adjusting knobs and indications through led devices only may be present, while more advanced systems may have graphical displays.
  • a welding machine may be adjusted for welding different metals, using different metal to be added, working in different weather conditions and finally adapting to the specific technical skills of the user.
  • a system comprising at least one electric and/or electronic apparatus, in particular a welding machine, and a removable control panel, said at least one electric and/or electronic apparatus comprising first electronic control and processing means connected to electronic detecting means from which it receives one or more signals of detection of one or more electric and/or physical quantities related to an operation of the apparatus, the first electronic control and processing means being configured to determine one or more operating conditions of said at least one electric and/or electronic apparatus on the basis of a set operation configuration, the first electronic control and processing means being connected to first input/output connection means configured to be connected to second input/output connection means of the removable control panel, the removable control panel comprising second electronic control and processing means and being configured to control said at least one electric and/or electronic apparatus by sending at least one operation configuration to the first electronic control and processing means, the removable control panel being further configured to receive from the first electronic control and processing means data related to said one or more detection signals and to give information depending on said received data related to said one or more detection signals through screenshots and/or
  • said at least one electric and/or electronic apparatus comprises a local input/output user interface comprising at least one manual control device and at least one display connected to the first electronic control and processing means, the system being characterised in that said second electronic control and processing means is configured to verify an acceptability of a change of one or more operating parameters of said at least one electric and/or electronic apparatus input by an operator through the manual control device, the first electronic control and processing means being configured to make said change effective only if verified as acceptable by said second electronic control and processing means, whereby the removable control panel is configured to supervise the first electronic control and processing means.
  • the system may have that:
  • the first electronic control and processing means is configured to send to said second electronic control and processing means data related to said change before making the same effective
  • said second electronic control and processing means is configured to verify the acceptability of said change and to communicate to the first electronic control and processing means the outcome of such verification
  • the first electronic control and processing means is configured to make said change effective only if said second electronic control and processing means has communicated its acceptability.
  • said change when said second electronic control and processing means communicates the acceptability of said change, said change may be made effective if an operator confirms the change within a pre-set time by interacting with said local input/output user interface, optionally by pressing a confirmation button
  • the removable control panel when the removable control panel sends said at least one operation configuration to the first electronic control and processing means, the removable control panel may further send one or more conditions of acceptability of one or more changes of one or more operating parameters inputtable by an operator through the manual control device, whereby the first electronic control and processing means is configured to determine an acceptability or not of a change of one or more operating parameters inputtable by an operator through the manual control device, the first electronic control and processing means being optionally configured to send to the removable control panel a signalling of an attempt of change.
  • said second electronic control and processing means may be configured to selectively verify an acceptability of a change of one or more operating parameters of said at least one electric and/or electronic apparatus input by an operator through the manual control device.
  • the removable control panel and/or the first electronic control and processing means may be configured to discriminate operators the changes of whom have to be subject to acceptability verification, said at least one electric and/or electronic apparatus being optionally provided with a radiofrequency identification or RFID sensor, configured to sense and read RFID transponders or tags, so as to identify one or more operators.
  • said first input/output connection means may comprise a first input/output connector, optionally a male connector, wherein the first input/output connector is of lightning type or USB type
  • said second input/output connection means may comprise a second input/output connector, optionally a female connector, wherein the first input/output connector is of lightning type or USB type
  • said first input/output connector being configured to be connected to said second input/output connector directly or via cable
  • the first electronic control and processing means may be configured to store data related to at least one fault of said at least one electric and/or electronic apparatus, and, when said first input/output connector is connected to said second input/output connector, the removable control panel may be configured to supply power to the first electronic control and processing means for retrieving said data related to said at least one fault.
  • the first input/output connection means may comprise a wireless communication module configured to be connected to wireless communication means with which said second input/output connection means is provided.
  • the removable control panel may be configured to simultaneously control a plurality of electric and/or electronic apparatuses.
  • the first electronic control and processing means may be configured to determine said one or more operating conditions of said at least one electric and/or electronic apparatus even when the connection between the removable control panel and the first electronic control and processing means is removed.
  • the removable control panel may be configured to control said at least one electric and/or electronic apparatus, when the removable control panel is connected to the first electronic control and processing means, by sending to the first electronic control and processing means at least one operation configuration dynamically variable on the basis of said received data related to said one or more detection signals.
  • said at least one manual control device may comprise at least one knob of an adjustment electronic device, optionally a potentiometer, and/or at least one switch, said at least one display comprising at least one alphanumeric display, optionally at least one three-digit alphanumeric display.
  • said at least one electric and/or electronic apparatus may be provided with a housing, optionally a recessed housing, provided with mechanical and/or magnetic means configured to interact with a frame of the removable control panel.
  • the first electronic control and processing means may comprise a microprocessor, the microprocessor optionally having a processing capability lower than the second electronic control and processing means.
  • the display may be a touch screen display, optionally a liquid crystal display, more optionally a colour liquid crystal display.
  • control panel may be provided with interface means configured to manually set said at least one operation configuration.
  • the removable control panel may be an electronic device provided with an internal rechargeable battery configured to supply the second electronic control and processing means, the battery being optionally configured to be recharged by the welding machine when the first input/output connection means is connected to the second input/output connection means and the welding machine is connected to mains.
  • the panel may be a tablet or a smartphone.
  • the present invention concerns an electric and/or electronic apparatus, in particular a welding machine, optionally an arc welding machine, the control panel of which is configured to control the functions of the apparatus (including configuration and monitoring), and that may be removed (optionally from a corresponding housing with which the same apparatus is provided) and connected to (optionally mounted onto) other electric and/or electronic apparatuses also configured to be connected and controlled by the removable control panel (optionally provided with a similar housing) for controlling all the functions of the new apparatus to which it is connected.
  • the removable control panel besides the setting of the parameters of the machine, is capable to automatically examine possible faults of the machine and to permit also to not skilled and/or not trained operators to repair the same.
  • the invention introduces a new technique for manufacturing the electric and/or electronic apparatuses, in particular welding machines, in which at least most part of the adjustment and control circuit portion is eliminated, which portion is instead entrusted to a smart removable control panel.
  • control panel temporarily mounted onto an apparatus (for instance a welding machine) recognise the latter, identifies its characteristics and potentialities and guides the user to set the various adjustment parameters for the apparatus operation (for instance the adjustment parameters of the desired welding process); similar operation modes occur when, instead of being physically mounted onto an apparatus, the control panel connects with the latter through wireless connection.
  • apparatus for instance a welding machine
  • the control panel transmits the adjustments to a simpler processing unit with which the apparatus is provided (for instance a microprocessor residing on the welding machine) that proceeds to autonomously manage the same apparatus (for instance the welding machine) and hence it allows to remove the control panel for using the same on a further different apparatus the operation of which the same panel is configured to control (for instance a welding machine of the same model of the former one, a welding machine of a model different from the former one, or another electric or electronic apparatus such as for instance a lathe or a microwave oven).
  • a simpler processing unit with which the apparatus is provided for instance a microprocessor residing on the welding machine
  • the apparatus for instance the welding machine
  • the removable smart control panel communicates with the apparatus through wired or wireless connection, thus implementing a sort of distributed processing, and in case of wireless connection it is possible to simultaneously connect a plurality of apparatuses to a single removable smart control panel, that may control and monitor the state and the operation of all the apparatuses simultaneously connected thereto.
  • control panel may be connected and may communicate with a first apparatus through wired connection and simultaneously the same control panel may be connected and may communicate with further apparatuses through wireless connection, whereby the same control panel may control and monitor the state and the operation of all the apparatuses connected thereto, namely the first apparatus connected through wired connection and the further apparatuses connected through wireless connection; in other words, even if the control panel is physically connected, through wired connection, only to one apparatus, the same control panel is configured to continue to communicate and control also other apparatuses through wireless connection.
  • the control panel could be also connected and communicate through wired connection with two or more apparatuses so as to control and monitor the state and the operation of all the apparatuses connected thereto through wired connection (and possibly one or more further apparatuses connected through wireless connection).
  • the system according to the invention is advantageously based on a sort of master-slave architecture between the control panel and the simpler processing unit with which the apparatus is provided (for instance a microprocessor residing on the welding machine).
  • an operator may interact with a simple local input/output user interface (e.g. a keypad, possibly a graphical keypad shown by the display that is a touch screen display) with which the apparatus is also provided and that is connected with the processing unit of the latter, by setting a change of one or more operating parameters of the apparatus, which change must be nevertheless enabled by the control panel before becoming effective, whereby the control panel may give the consent to such change or may prevent from becoming effective on the apparatus on which it has been set.
  • a simple local input/output user interface e.g. a keypad, possibly a graphical keypad shown by the display that is a touch screen display
  • the control panel may give the consent to such change or may prevent from becoming effective on the apparatus on which it has been set.
  • the apparatus may be a welding machine dedicated to any welding process, in particular a SMAW (or MMA), GMAW (or MIG or MAG), TIG or even plasma process.
  • SMAW or MMA
  • GMAW or MIG or MAG
  • TIG or even plasma process.
  • the removable control panel constantly monitors the operation of the apparatus and the process that is intended to execute, e.g. the welding process, through the characteristic parameters thereof, such as, for instance in case of a welding machine, voltage, current, arc length, speed, amount of gas.
  • Such parameters when not directly measurable, are estimated on the basis of the results of the real time processing of one or more mathematical model.
  • the operator is also assisted with speech and/or video messages played on the removable control panel which may suggest the correction of parameters for achieving a good result, e.g. a good welding.
  • both skilled and not skilled operators may operate in complete safety with the assistance of the removable control panel; this is extremely useful, since many electric and/or electronic apparatuses, such as for instance welding machines, have a wide diffusion and are used not only by specifically trained operators but also by not trained operators, as it particularly occurs in the field of leisure.
  • the assistance through speech and/or video messages is optionally extended to playing the instruction manual, as well as to all that information aimed at the identification of the service centres and supply centres for consumable materials, within the area where the apparatus has been sold and/or is used.
  • Figure 1 shows a front view of a first embodiment of a welding machine according to the invention in a first configuration
  • Figure 2 shows a front view of the welding machine of Figure 1 in a second configuration
  • FIG 3 shows a circuit scheme of the control electronics of the welding machine of Figure 1.
  • Figures 1 and 2 show a front view of a MMA welding inverter machine in a first configuration and in a second configuration, respectively, wherein in the first configuration the removable control panel 10 is mounted on the front wall of the welding machine, while in the second configuration the removable control panel 10 is not mounted on (i.e. it is removed from) the front wall of the welding machine.
  • the front wall of the machine is provided with a housing 20 (that is optionally a recessed housing provided with mechanical and/or magnetic means configured to interact with the frame of the panel 10) wherein it is possible to insert the panel 10 having a liquid crystal display, or LCD, 15; moreover, the front wall of the machine is provided with a positive output terminal 01 and a negative output terminal 02.
  • the panel 10 When inserted in the housing 20, the panel 10 has an input/output connector (not shown in Figures 1 and 2), optionally a female connector (by way of example and not by way of limitation of lightning or USB type), that may be connected directly or via cable to an input/output connector 21, optionally a male connector, arranged in the housing 20 and connected to a microprocessor (not shown in Figures 1 and 2) residing on the machine; alternatively, the panel 10 may be connected to the microprocessor (not shown in Figures 1 and 2) residing on the machine through wireless connection.
  • an input/output connector (not shown in Figures 1 and 2), optionally a female connector (by way of example and not by way of limitation of lightning or USB type), that may be connected directly or via cable to an input/output connector 21, optionally a male connector, arranged in the housing 20 and connected to a microprocessor (not shown in Figures 1 and 2) residing on the machine; alternatively, the panel 10 may be connected to the microprocessor (not shown in Figures 1 and 2)
  • the panel 10 When inserted in the housing 20, the panel 10 is placed over and covers some simple manual control devices and/or displays of the machine arranged in the housing 20 (even if such placement is not an essential feature of the machine), such as for instance knobs of adjustment electronic devices (e.g. potentiometers), switches and displays optionally constituted by alphanumeric displays, which form a local user interface.
  • knobs of adjustment electronic devices e.g. potentiometers
  • switches and displays optionally constituted by alphanumeric displays, which form a local user interface.
  • the housing 20 of the welding machine shown in the Figures is provided with a local user interface comprising two knobs 22 and 23 of adjustment potentiometers and two three-digit alphanumeric displays 24 and 25, which are visible in Figure 2.
  • circuit diagram of Figure 3 is a power AC/DC converter of the dual switch forward type (sometimes called asymmetric bridge).
  • the electronics is power supplied by a single phase mains, to which it connects through phase and neutral terminals F and N, while a third terminal GND is connected to the ground of the mains; in particular, the three terminals F, N and GND are part of an input interface consisting of an electrical plug SP1.
  • EMI filter an electromagnetic interferences
  • PI a first diode bridge power rectifier
  • rectified and smoothed current is re-converted in a high frequency (preferably ranging from 50 to 100 KHz) one by a DC/AC power converter Bl for power supplying the primary of a transformer TR1, the secondary of which is connected to an output rectifying stage having two output terminals, positive 01 and negative 02, which deliver arc voltage and current.
  • EMI filter El that is preferably a passive filter, limits electromagnetic disturbance produced by the machine and led towards the mains.
  • the DC/AC power converter Bl is of the dual switch forward type (even if this is not an essential feature of the invention) and comprises two IGBTs II and 12, the gates of which are driven by a pulse width modulation, or PWM (Pulse Width Modulation), signal generator F2 for creating a pulse voltage on the primary of the transformer TRl, also thanks to the presence of the two blocking diodes Dl and D2.
  • PWM Pulse Width Modulation
  • the transformer TRl besides to lowering the voltage level down to the value needed for welding, ensures a galvanic insulation of the "welding output” section (connected to the output terminals 01 and 02) from the "mains" section.
  • the output rectifying stage comprises a second diode bridge power rectifier P2, that receives the current delivered by the secondary of the transformer TRl, and an inductor L2, connected between the rectifier P2 and the positive output terminal 01, so as to rectify and smooth the output voltage of the transformer TRl.
  • the welding machine is controlled by a microprocessor Ml (provided with a memory, not shown in Figure 3), that is connected to the power electronics and to a plurality of transducers and sensors from which it receives a plurality of detections of electrical quantities characteristic for the machine operation.
  • Ml provided with a memory, not shown in Figure 3
  • the welding machine shown in the Figures may execute the welding process through acid, basic and cellulose electrodes, as well as aluminium electrodes and still other electrodes. Each one of these electrodes requires different adjustments and particular level of accuracy in order to obtain an optimal welding. Therefore, the microprocessor Ml of the control electronics of Figure 3 controls the operation of the welding machine, being capable to adjust several operating parameters of the control electronics and, consequently, of the welding machine. In particular, the microprocessor is configured to execute sophisticated instructions and to transmit specific controls to the various circuit sections.
  • Such sophisticated instructions may be updated and controlled by the control panel 10, whereby a fixed operation logic is no more implemented at the time of manufacture of the welding machine, rather updatable instructions are implemented for adapting to logics acquired by the same user through the control panel 10 and to latest manufactured materials.
  • the microprocessor Ml is connected to a plurality of transducers and sensors from which it receives a plurality of detections of electrical quantities characteristic of the various circuit sections and, consequently, indicative of the operation of the control electronics and of the welding machine.
  • microprocessor Ml is connected:
  • a third transducer H3 namely a current transducer, to a shunt resistor RSI for sensing the current delivered by the machine at the output terminals 01 and 02, i.e. the arc current;
  • un fourth transducer H4 namely a voltage transducer, to the output terminals 01 and 02 for sensing the value of the output voltage
  • a fifth transducer H5 namely a current transducer
  • a shunt resistor RS2 for sensing the current drawn by a fan Z2 for cooling the machine, on the basis of which the microprocessor Ml is capable to monitor the fan operation.
  • microprocessor Ml is connected:
  • a resistor RA1 that transduces the output voltage of the EMI filter El into a current, adapted so as to be capable to supply power to the LED of the optoisolator II, whereby, when an AC power supply voltage adapted to the operation of the machine is present, the LED within the optoisolator II turns on and the phototransistor of the optoisolator II provides the microprocessor Ml with a corresponding impulse signal of logic state at the same frequency of the mains;
  • a resistor RA2 that transduces the output voltage of the first rectifier PI into a current, adapted so as to be capable to supply power to the LED of the optoisolator 12, whereby, when a power supply voltage adapted to the operation of the machine is present, the LED within the optoisolator 12 turns on and the phototransistor of the optoisolator 12 provides the microprocessor Ml with a corresponding signal of logic state;
  • a fourth optoisolator 14 that transduces the voltage at the output terminal of the generator F2 driving the second IGBT J2 into a current, adapted so as to be capable to supply power to the LED of the optoisolator 14, whereby, when a voltage adapted to drive the IGBT J2 is present, the LED within the optoisolator 14 turns on and the phototransistor of the optoisolator 14 provides the microprocessor Ml with a corresponding signal of logic state;
  • a resistor RA5 that transduces the voltage on the primary of the transformer TRl into a current, adapted so as to be capable to supply power to the LED of the optoisolator 15, whereby, when a pulse voltage adapted to supply power to the primary of the transformer TRl is present, the LED within the optoisolator 15 turns on and the phototransistor of the optoisolator 15 provides the microprocessor Ml with a corresponding signal of logic state;
  • a resistor RA6 that transduces the voltage on the secondary of the transformer TRl into a current, adapted so as to be capable to supply power to the LED of the optoisolator 16, whereby, when an AC voltage adapted to supply power to the second rectifier P2 is present, the LED within the optoisolator 16 turns on in a pulsed way and the phototransistor of the optoisolator 16 provides the microprocessor Ml with a corresponding signal of logic state;
  • the LED within the optoisolator 17 turns on and the phototransistor of the optoisolator 17 provides the microprocessor Ml with a corresponding signal of logic state.
  • the microprocessor Ml is capable to monitor and recognise the malfunctioning circuit sections.
  • circuit sections may be identified as: the power supply section comprising the plug SPl; the EMI filter El; the first rectifier PI; the smoothing capacitor CI; the generator F2 driving the IGBTs Jl and J2; the IGBTs Jl and J2; the power transformer TR1; the service transformer TRO; the second rectifier P2; the output inductor L2; and the fan Z2 for cooling the machine.
  • the microprocessor Ml monitors the operation of the first rectifier PI and of the capacitor CI on the basis of the signal that it receives from the optoisolator 12.
  • the microprocessor Ml processes such signal such that, if the output signal of the optoisolator 12 is always on, than the capacitor CI operates correctly since it manages to correctly smooth the voltage rectified by the rectifier PI; if, on the contrary, the output signal of the optoisolator 12 changes state with a frequency equal to twice the one of the input voltage of the rectifier PI sensed by the optoisolator II (e.g.
  • the rectifier PI correctly operates but the capacitor CI does not smooth; differently, if the output signal of the optoisolator 12 changes state with a frequency equal to the one of the input voltage of the rectifier PI (e.g. 50Hz), then some diodes of the rectifier PI are damaged.
  • the microprocessor Ml executes the processing for monitoring the operation of the first rectifier PI and of the capacitor CI taking account of the operation of the EMI filter El, that is monitored on the basis of the signal that the microprocessor Ml receives from the optoisolator II.
  • the microprocessor Ml monitors the operation of the generator F2 driving the IGBTs Jl and J2 on the basis of the signals that it receives from the optoisolators 13 and 14.
  • the microprocessor Ml processes such signals so as to recognise a correct operation of the generator F2 if, in the instant when the microprocessor Ml sends to the generator F2 the control signals for turning the IGBTs Jl and J2 on, the optoisolators 13 and 14 respectively provide an on output signal, while in the instant when the microprocessor Ml does not send any signal to the input of the generator F2, then the two optoisolators 13 and 14 have not to give any feedback signal toward the microprocessor Ml.
  • the microprocessor Ml monitors the operation of the other circuit sections and the various electric quantities characteristic of the operation of the machine (e.g. power supply voltage, output voltage and current) on the basis of the signals coming from the transducers HI, H3, H4, H5 and H6 and of the signals coming from the optoisolators 15, 16 and 17. Also, the microprocessor Ml monitors the operation temperature of the machine on the basis of the signal coming from the transducer H2.
  • the various electric quantities characteristic of the operation of the machine e.g. power supply voltage, output voltage and current
  • microprocessor Ml may be connected to other electronic devices and/or transducers and/or sensors, generically represented in Figure 3 through the block Zl, such as for instance:
  • the apparatus when it is a welding machine operating according to an arc welding process with metal protected by gas or GMAW (Gas Metal Arc Welding), or when it is a welding machine operating according to an arc welding process with infusible tungsten electrode protected by inert gas, or TIG (Tungsten Inert Gas), or when it is a welding machine operating according to a plasma welding or cutting process;
  • GMAW Gas Metal Arc Welding
  • TIG Tusten Inert Gas
  • the microprocessor Ml receives information on the environmental conditions which may affect the welding process in order to control the operation of the electronics of Figure 3 so as to optimise the process by adapting the same to such environmental conditions, and to possibly inform the operator through speech and/or video messages played on the control panel 10 (or on a speaker controlled by the microprocessor Ml) about the possible necessity of preheating the piece to be welded;
  • transducer connected to a shunt resistor for sensing the current delivered by the first rectifier PI;
  • a radiofrequency identifier or RFID sensor for sensing and reading RFID, active or passive, transponders or tags, in order to identify operators and/or consumables provided with RFID tags (e.g. an electrode for SMAW welding or a wire coil for GMAW welding), in order to possibly also signal and/or inform the operator through speech and/or video messages played on the control panel 10 (or on a speaker controlled by the microprocessor Ml) about adequacy of the consumable;
  • RFID tags e.g. an electrode for SMAW welding or a wire coil for GMAW welding
  • a GPS or AGPS georeferenced position sensor for detecting a georeferenced position of the machine
  • a digital transducer for sensing the height, based by way of example, and not by way of limitation, on the MEMS pressure sensor LPS001D available from the company ST Microelectronics;
  • a codec (audio encoder/decoder) device for managing sounds and speech messages, provided with a mass storage memory storing speech messages, which codec device is capable to convert digital data (processed starting from signals delivered by the microprocessor Ml or retrieved from the memory of the same codec device) into audio signals which are then amplified by the same codec device for being played by a speaker connected to the latter; possibly, the codec device could be also incorporated into the microprocessor Ml, whereby in this case the block Zl of Figure 3 would represent the speaker.
  • the signals received from the various sensors and transducers are instantaneously processed by the microprocessor Ml, and optionally information related to any detected malfunction is stored in the memory of the microprocessor Ml along with all the other information preceding and simultaneous to the instant of the malfunction (such as, for instance, the power supply voltage, the output current, the operation of the fan Z2 and the temperature).
  • the microprocessor Ml may be connected to the control panel 10; alternatively, the microprocessor Ml may be connected to the control panel 10 via wireless connection implemented through a communication module Z5 connected to and controlled by the microprocessor Ml.
  • the wireless communication module Z5 may be integrated within the machine or it may comprise an interface, e.g. a USB interface, configured to receive an external wireless communication device (e.g. a conventional wireless communication USB stick, provided with a housing configured to house a smart card).
  • the removable control panel 10 may be configured to simultaneously connect via wireless connection to a plurality of microprocessors of other machines for simultaneously controlling the operation of both the machine to which it is connected via wired connection and a plurality of other welding machines (or even a plurality of different electric and/or electronic apparatuses) each one provided with a microprocessor connected via wireless connection to the panel 10.
  • the removable control panel 10 may be configured to simultaneously connect via wireless connection to a plurality of microprocessors for simultaneously controlling the operation of a plurality of welding machines (or even a plurality of different electric and/or electronic apparatuses) each one provided with a microprocessor of the plurality of microprocessors connected via wireless connection to the panel 10.
  • the removable control panel 10 is configured to provide the microprocessor Ml, when the panel and the microprocessor are connected to each other, with all the data for the settings of the welding machine (i.e. it may configure the welding machine), as well as for receiving data coming from one or more of the electronic devices and/or sensors and/or transducers connected to the microprocessor Ml (such data may possibly have been processed by the microprocessor Ml, but this is not essential, and the microprocessor Ml may also process only part of the data coming from the electronic devices and/or sensors and/or transducers connected to the microprocessor Ml), for processing such data and for re-sending to the microprocessor Ml the values of the output signals which have to be generated by the microprocessor Ml for controlling the machine operation.
  • This allows to have a microprocessor Ml with a not very high processing capability, and hence inexpensive and with simple operation and configuration.
  • the removable control panel 10 may be any electronic device provided with an internal rechargeable battery for supplying power to the electronics of the panel 10, processing means, memory means, input/output interface means for the connection via cable and wireless to the welding machine (or more generally with an electric and/or electronic apparatus), a keypad and a display, optionally an LCD more optionally a colour LCD, and optionally a speaker; in particular, the keypad may be a graphical keypad shown by the display that is a touch screen display (i.e. sensitive to touch).
  • the control panel 10 may connect through the wireless input/output interface means to the Internet network, for receiving updates on the processing algorithms for controlling the machine and/or on the processing algorithms of the microprocessor Ml and/or on the selectable settings for the welding machine.
  • the battery may be recharged also by the welding machine through the connection of the input/output connector of the panel 10 to the input/output connector 21 of the machine.
  • the microprocessor of the removable control panel 10 may be configured to play videos on the display.
  • the removable control panel 10 could be a tablet or a smartphone.
  • the removable control panel 10 and the welding machine (or more generally the electric and/or electronic apparatus) on which the same panel may be mounted may be also manufactured and marketed independently from one another. Therefore, the present invention concerns: the system comprising the welding machine (or more generally the electric and/or electronic apparatus) and the removable control panel 10; the welding machine (or more generally the electric and/or electronic apparatus) configured to be connected to and controlled by the removable control panel 10; and the removable control panel 10 configured to be connected to and controlled by the welding machine (or more generally the electric and/or electronic apparatus).
  • the welding machine may be manufactured and marketed with the microprocessor Ml having a base configuration of traditional type, for instance adapted to weld a rutile electrode.
  • the user of the welding machine may insert a control panel 10 (purchased along with the welding machine or previously purchased and hence already available to the user) in the housing 20 (of Figure 2) configured to be connected to the microprocessor Ml of the welding machine so as to control the operation of the same machine; in particular, the control panel 10 is configured to configure the operating parameters of the welding machine, for monitoring the state of the components of the welding machine, as well as for providing an operator with information through speech and/or video messages concerning safety rules, technical rules for the correct management of the parameters of the welding machine and rules for the good outcome of a welding.
  • the removable control panel 10 may be configured to be mounted on a plurality of different welding machines (having a similar housing for the panel), and to recognise the type of machine on which it is mounted so as to be then capable to manage and adjust all the parameters of the machine on which it is mounted.
  • the removable control panel 10 recognises the machine, graphically presents on the display 15 all the possibilities of change of the various operating parameters of the latter (e.g. depending on the type of welding process), optionally allows the operator to input the characteristics of the welding electrode (e.g., type and size) and/or the characteristics of the materials to weld, and the panel 10 processes the best solution to make an optimal welding; in particular, the panel 10 could acquire some of these and other data, such as for instance the characteristics of the welding electrode, the environmental temperature and humidity, directly from the microprocessor Ml that receives the detections from its own electronic devices, sensors and transducers (e.g.
  • the operator may interact with the local input/output interface of the panel 10 (e.g. a keypad, possibly a graphical keypad shown by the display that is a touch screen display), changing the operating parameters of the welding process according to his/her own experience.
  • a keypad possibly a graphical keypad shown by the display that is a touch screen display
  • the panel 10 sends to the microprocessor Ml residing on the machine the data for setting the operation of the welding machine and the information about which data must be displayed on the alphanumeric displays 24 and 25 (also visible in Figure 3) and about which quantities may be changed through the interaction with the knobs 22 and 23 (also visible in Figure 3), taking into account that also one single quantity could be changed; once the data for settings are sent, the control panel 10 may be removed from the housing 20, because the welding machine is set for the desired use.
  • control panel 10 and the microprocessor Ml of the machine capable to be connected and controlled by the panel 10 (i.e. the microprocessors Ml of the machines capable to be connected and controlled by the same panel 10), may be configured to implement a sort of master-slave architecture wherein the control panel 10 supervises the microprocessor Ml (the microprocessors Ml) so as to enable or not possible changes of one or more operating parameters of the machine, and consequently of the welding process, made by an operator through the local input/output user interface, i.e. through the knobs 22 and 23, of the same machine.
  • the microprocessor Ml is configured to send to the control panel 10 data related to such change before making the same effective
  • control panel 10 is in turn configured to verify the acceptability of such change, on the basis of the welding program of which it has preliminarily provided the microprocessor Ml with the operation configuration, and to enable or not, depending on whether such change is acceptable or not, the same change and to communicate to the microprocessor Ml the outcome of such verification, and
  • the microprocessor Ml is configured to make said change effective only if the control panel 10 has communicated its acceptability.
  • a change could be recognised as acceptable by the control panel 10 if the value of the parameter or its percentage variation fall within a range, possibly adaptive to the environmental conditions.
  • control panel 10 could require, before the change is made effective, that the operator confirms the same change within a pre-set time by interacting with the local input/output user interface of the machine (e.g. for instance by pressing a specific button).
  • the system according to the invention may be configured so that the control panel 10, when it sends to the microprocessor Ml the operation configuration, also sends conditions of acceptability of the changes input through the local input/output user interface of the machine, whereby the microprocessor Ml is configured to determine the acceptability or not of the input changes without the necessity to start a communication with the control panel 10, and the microprocessor Ml may be configured to send to the control panel 10 only a signalling of the attempt of change so that the latter may possibly show an alarm for a supervisor.
  • inventions may be configured so as to select the operation mode between a supervision mode, wherein the control panel 10 supervises the microprocessor Ml (the microprocessors Ml) so as to enable or not possible changes of one or more operating parameters of the machine, and a free mode, wherein the changes input through the local user interface of the machine are not subject to the verification of acceptability.
  • this could be implemented through a specific switch with which the machine is provided, and/or through specific software controls (e.g. graphical buttons) operatable on a user interface of the control panel 10.
  • FIG. 1 For purposes of example, the changes made by specific skilled operators or during operations of maintenance of the machine could be always allowed, and hence they could be exempted from the preliminary verification made by the control panel 10, while the changes made by not particularly skilled operators could be always subject to such verification.
  • the display 15 of the control panel 10 may be configured to play, when selected by the operator, a video related to a welding course for a type of electrode that has to be used in the welding, and possibly a video related to first aid instructions for accidents occurring for the type of welding process in progress and for the type of welding machine set by the control panel 10.
  • the removable control panel 10 may be configured to give information on the type of fault and its solution.
  • the removable control panel 10 may be configured to give information about the type of fault and its solution even when the machine cannot be power supplied (e.g. due to a short-circuit on the cable connected to the mains through the plug SPl), in particular when the microprocessor Ml is advantageously configured to store in its memory the data related to the faults (for instance one or more of the following data: circuit section and/or electronic component where the fault has occurred; type of fault; date and time of fault detection).
  • the removable control panel 10 may be configured to supply power to the microprocessor Ml and retrieve from the memory of the latter the data related to the faults.
  • such operation mode may be combined with the control of the master-slave architecture type illustrated above (wherein the control panel 10 enables or not the changes sat by an operator on the local user interface of the machine), or it may be also independent from such type of control.
  • the removable control panel 10 may be also configured to play a video related to the circuit section and/or the electronic component where the fault has occurred, for connecting with the supplier of parts for maintenance and repair of the machine, and for playing a video related to the replacement of such circuit section and/or the electronic component and to the test so as to assist the operator executing the repair (e.g. a tester).
  • a tester e.g. a tester
  • the base configuration of the microprocessor Ml with which the welding machine is marketed may be later supplemented with other configurations and/or updated through the settings sent by the removable control panel 10.
  • the removable control panel 10 When the removable control panel 10 is connected to the microprocessor Ml of the welding machine, instantaneously the removable control panel 10 automatically gets one or more data of recognition of the welding machine, such as: the type/model, the serial number, the date of manufacture, the firmware version of the microprocessor Ml (including the version of the base configuration), the electronics version, the effective operation hours, the state of the hardware and the presence of possible alarms.
  • the type/model the serial number
  • the date of manufacture the firmware version of the microprocessor Ml (including the version of the base configuration)
  • the electronics version including the version of the base configuration
  • the effective operation hours the state of the hardware and the presence of possible alarms.
  • the removable control panel 10 provides the operator on the display 15 with a summary screenshot with some of the data received from the welding machine, and it allows the operator to set one or more adjustable parameters, such as for instance the output voltage, the value of hot start (i.e. the initial time during which the welding machine delivers an overcurrent), the values of anti-stick (i.e. the duration of the time interval during which the welding machine heats the tip with a current of reduced value possible settable for allowing the removal of the electrode that has stuck to the material to be welded, avoiding an overload of the power AC/DC converter), the value of arc- force (i.e.
  • the removable control panel 10 may be also configured to store one or more pre-set welding programs depending on the specific welding conditions, such as the type of materials to be welded, and/or their thickness. Once the adjustable parameters of the welding process have been selected and/or customised, the removable control panel 10 sends all the setting information to the microprocessor Ml.
  • the microprocessor Ml gives all the data, possibly processed, related to the detections and the state of the various electronic devices, sensors and transducers of the welding machine to the removable control panel 10, that processes these data and graphically shows on the display 15 the information necessary in that moment, such as for instance output voltage and current.
  • the same panel 10 may be configured to send adaptive setting information to the microprocessor Ml dynamically variable on the basis of the data related to the detections and the state of the various electronic devices received from the microprocessor Ml.
  • the housing 20 wherein it is possible to insert the control panel 10 illustrated with reference to the welding machine shown in the Figures is not an essential feature of the invention, whereby other embodiments of the welding machine may be not provided with such a housing and the panel may connect to the microprocessor of the machine through the respective input/output connectors (in this case, the connector of the machine is arranged on a wall, advantageously an horizontal wall, of the frame that may support the panel) and/or through via wired and/or wireless connection.
  • any electric and/or electronic apparatus e.g. battery chargers, safes with electronic control, burglar alarms, motor vehicle controlling electronic devices, machine tools such as for instance drills, circular saws and lawn mowers, electrical boxes, electromedical equipments, electronic apparatuses and devices for controlling civil or industrial electric traction vehicles
  • a household appliance e.g. washing machines, electric ovens, microwave ovens, dishwashers, refrigerators, cooking machines
  • for controlling and monitoring the operation of the apparatus or household appliance provided with a microprocessor with a not very high processing capability, and for giving information through screenshots and/or videos played on the display of the control panel, as well as possible speech messages.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Arc Welding Control (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un système comprenant au moins un appareil électrique et/ou électronique, en particulier une machine à souder, et un panneau de commande amovible (10), le premier moyen de commande et de traitement électronique (Ml) étant conçu pour déterminer une ou plusieurs conditions de fonctionnement dudit ou desdits appareils électriques et/ou électroniques sur la base d'une configuration de fonctionnement définie, le premier moyen de commande et de traitement électronique (Ml) étant connecté à un premier moyen de connexion d'entrée/sortie (21, Z5) conçu pour être connecté à un second moyen de connexion d'entrée/sortie (Z4) du panneau de commande amovible (10), le panneau de commande amovible (10) comprenant un second moyen de commande et de traitement électronique et étant conçu pour commander ledit ou lesdits appareils électriques et/ou électroniques par l'envoi au premier moyen de commande et de traitement électronique (Ml) d'au moins une configuration de fonctionnement, ledit ou lesdits appareils électriques et/ou électroniques comprenant une interface utilisateur d'entrée/sortie locale comprenant au moins un dispositif de commande manuelle (22, 23) et au moins un écran (24, 25) connecté au premier moyen de commande et de traitement électronique (Ml), le système étant caractérisé en ce que ledit second moyen de commande et de traitement électronique est conçu pour vérifier l'acceptabilité d'un changement d'un ou de plusieurs paramètres de fonctionnement dudit ou desdits appareils électriques et/ou électroniques fournis en entrée par un opérateur au moyen du dispositif de commande manuelle (22, 23), le premier moyen de commande et de traitement électronique (Ml) étant conçu pour rendre ledit changement effectif uniquement s'il est vérifié comme acceptable par ledit second moyen de commande et de traitement électronique, le panneau de commande amovible (10) étant ainsi conçu pour superviser le premier moyen de commande et de traitement électronique (Ml).
PCT/IB2015/052263 2014-03-27 2015-03-27 Dispositif électrique et/ou électronique, en particulier machine à souder, doté d'un panneau de commande amovible Ceased WO2015145391A2 (fr)

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ITRM20140161 2014-03-27

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