Sensor-based power controls for a welding system

#The invention relates generally to welding systems, and, more particularly, to sensing systems for controlling power supplies or accessories of a welding system using motion sensors.

#Welding is a process that has become ubiquitous in various industries for a variety of types of applications. For example, welding is often performed in applications such as shipbuilding, aircraft repair, construction, and so forth. The welding systems often include power sources that may generate power for consumption during the welding process. However, these power sources may generate power even when unneeded due to inactivity of the welding torch. Furthermore, if the power sources are inactive or producing reduced power until a demand event (e.g., a trigger is pressed), there may be a period of time during which power is desired but unavailable.

#In a first embodiment, a welding system includes a power source and a torch motion sensing system associated with a welding torch and configured to sense welding torch orientations or movements. The welding system also includes a processing system communicatively coupled to the torch motion sensing system. The processing system is configured to determine movement of the welding torch prior to a welding demand from the welding torch, and to send an indication to the power source to provide power at a generation level sufficient to operate the welding torch.

#These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

#FIG. 1 is a block diagram of an embodiment of a welding system utilizing a power supply and a welding torch with motion sensors;

#FIG. 2 is a flowchart of an embodiment of a power control process that may be used by the welding system of FIG. 1;

#As will be described in detail below, provided herein are systems and methods for using motion (e.g., inertial) sensors in a welding torch to determine likelihood of power demand prior to actual demand to reduce delays in power availability and/or waste of generated power. By determining that a welding torch is being moved, the welding system may determine demand is likely imminent and that a higher level power generation state should be initiated even before explicit requests (e.g., pressing a trigger on the torch). The generation of power when the welding torch determines that the demand is likely imminent allows a power source to ramp up power earlier, thereby reducing or eliminating a deficit in power available at the time of initial demand.

#Turning now to the figures, FIG. 1 is a block diagram of an embodiment of a welding system 10 in accordance with the present techniques. The welding system 10 is designed to produce a welding arc 12 with a workpiece 14 (e.g., pipe). The welding arc 12 may be generated by any type of welding system or process, and may be oriented in any desired manner. For example, such welding systems may include gas metal arc welding (GMAW) systems, and may utilize various programmed waveforms and settings. The welding system 10 includes a power supply 16 (e.g., engine-driven generator in some embodiments) that will typically be coupled to a power source 18, such as a power grid, an engine, or a combination thereof (e.g., hybrid power). Other power sources may, of course, be utilized including generators and so forth. In the illustrated embodiment, a wire feeder 20 is coupled to a gas source 22 and the power source 18, and supplies welding wire 24 to a welding torch 26. The welding torch 26 is configured to generate the welding arc 12 between the welding torch 26 and the workpiece 14. The welding wire 24 is fed through the welding torch 26 to the welding arc 12, melted by the welding arc 12, and deposited on the workpiece 14.

#The wire feeder 20 will typically include wire feeder control circuitry 28, which regulates the feed of the welding wire 24 from a spool 29 and commands the output of the power supply 16, among other things. Similarly, the power supply 16 may include power supply control circuitry 30 for controlling certain welding parameters and arc-starting parameters. In certain embodiments, the wire feeder control circuitry 28 or the power supply control circuitry 30 may be include software, hardware, or a combination thereof. For example, in certain embodiments, the wire feeder control circuitry 28 and/or the power supply control circuitry 30 may include a processor and memory configured to store instructions to be executed by the processor. In some embodiments, the wire feeder control circuitry 28 may communicate with the power supply control circuitry 30 through a weld cable 31 that is also used to provide power to the wire feeder 20. The spool 29 of the wire feeder 20 will contain a length of welding wire 24 that is consumed during the welding operation. The welding wire 24 is advanced by a wire drive assembly 32, typically through the use of an electric motor under control of the control circuitry 28. In addition, the workpiece 14 is coupled to the power supply 16 by a clamp 34 connected to a work cable 36 to complete an electrical circuit when the welding arc 12 is established between the welding torch 26 and the workpiece 14.