Coolant safety system for automated welding apparatus

In an automated welding machine, where a flow of liquid coolant is supplied to welding components on the machine from a source of coolant and then return to the source of coolant, the improvement comprising:

• a supply sensor for measuring the supply flow rate of coolant in a supply coolant line to welding components;
• a return sensor for measuring the return flow rate of coolant in a return coolant line from the welding components;
• a microprocessor adapted to compare the supply flow rate and return flow rate and detect differences between said two rates, said microprocessor adapted to compare the detected differences to a leak threshold value, and said microprocessor adapted to generate a valve shut-off signal in the event of a detected difference in flow rates exceeds the leak threshold value;
• a valve in the supply coolant line responsive to the valve shut-off signal to shut off the flow of coolant in response thereto;
• and
• a modular electrical enclosure and an electrical sensor assembly.

In an automated welding machine, where a flow of liquid coolant is supplied to welding components on the machine from a source of coolant and then returned to the source of coolant, the improvement comprising:

• a supply sensor for measuring the supply flow rate of coolant in a supply coolant line to welding components;
• a return sensor for measuring the return flow rate of coolant and a return coolant line from the welding components;
• a microprocessor located within a water saver unit adapted to compare the supply flow rate and return flow rate and detect differences between said two rates, a microprocessor adapted to compare the detected differences to a leak threshold value, and the microprocessor adapted to generate a valve shut-off signal in the event of a detected difference in flow rates exceeds the leak threshold value;
• a weld timer circuit for shutting off water after a predetermined period of inactivity;
• a modular power and valve cord component including a rapid change connector;
• a history circuit capable of counting amount of time unit has been on and counting number of leaks and low flow conditions;
• a calibration circuit for auto zeroing;
• and
• an internal auxiliary flow monitor unit said auxiliary flow monitor unit using a separate circuit independent from a water saver main circuit.

A method of controlling a water saver apparatus which is connected to a coolant line in an automated welding machine where the coolant lines supply welding components on the machine from a source of coolant and then return to the source of coolant through the water saver apparatus, said method including the steps of:

• initializing said water saver for a specific welding job;
• monitoring main and auxiliary circuits;
• detecting leaks by measuring difference in flow to and from said water saver;
• activating alarm if flow is below a predetermined value;
• and
• auto calibrating apparatus upon leak condition or user bypass.

A method of controlling a water saver apparatus which is connected to a coolant line in an automated welding machine where the coolant lines supply welding components on the machine from a source of coolant and then return to the source of coolant through the water saver apparatus, said method including the steps of:

• clearing variables;
• setting interrupts for power down of a microprocessor and setting a time interval for sensor readings;
• determining if buttons and switches are activated;
• calculating flow in supply and return lines if predetermined time interval has passed;
• comparing flow rates with predetermined values;
• and
• turning off flow of coolant if bad flow condition exists for predetermined period of time.