Smart controller for exothermic welding and related systems and methods

A controller for igniting weld material in an exothermic welding process, the controller comprising:

• an enclosure;
• a battery connection feature on the enclosure configured to connect the controller to a battery;
• an electronic circuit in the enclosure;
• and
• a connection on the enclosure and configured to receive a first end of a cable with a second, opposite end of the cable configured to be received at a mold holding the weld material,
• wherein the electronic circuit comprises a processor that is configured to, responsive to receiving an input signal, direct an ignition current to flow from the battery to the second end of the cable,
• wherein the electronic circuit comprises a wireless module configured to receive a wireless signal from a portable electronic device as the input signal,
• wherein the electronic circuit is configured to display a warning or emit an alert when the cable is not properly connected to the controller or the mold,
• wherein the electronic circuit is configured to determine a distance between the controller and the portable electronic device, and
• wherein the processor is configured to direct current from the battery to the second end of the cable only if the distance is equal to or greater than a predetermined distance.

An exothermic welding system comprising:

• a battery;
• a controller configured to electrically connect to the battery;
• and
• a cable comprising a first end configured to connect to a connection of the controller and a second end configured to connect to an igniter, with a wire filament, attached to a mold containing weld material,
• wherein the controller is configured to, in response to receiving an input signal, direct ignition current from the battery to the cable to ignite the weld material,
• wherein the input signal is selectively provided (i) as a wireless signal from a portable electronic device or (ii) in response to actuation of an actuator of the controller,
• wherein the controller is configured to display a warning or emit an alert when the cable is not properly connected to the controller or the mold,
• wherein the input signal is provided as a wireless signal from a portable electronic device,
• wherein the controller is configured to determine a distance between the controller and the portable electronic device, and
• wherein the controller is configured to direct current from the battery to the second end of the cable only if the distance is equal to or greater than a predetermined distance.