Remotely controlled welding machine

Abstract

The present invention is directed to a remotely controlled welding machine. A remote control uses the welding circuit to transfer information to a welding power source. The information to be communicated to the power source includes welding power source output command information (amperage/voltage control), welding circuit on/off information (power source output contactor control), and power source mode control (constant voltage/constant current). A transmitter transmits the desired welding operational parameters to a receiver disposed in the power source. The transmitter is constructed to use only a small amount of power which, preferably, is supplied by one or two low voltage replaceable and/or rechargeable batteries. Additionally, an open circuit voltage is not created between the power source and an electrode holder when an arc is not present.

1 - 25 . (canceled)  
   
   
       26 . A wire feeder including a motor driving a set of feed rolls to force a welding wire from a spool through a welding torch to a welding operation, said wire feeder having: 
 an input lead to be connected to the output terminal of a remotely located power source having an on condition and an off condition where a welding current is directed to said output terminal only when said source is in said on condition;    a weld starting trigger with a weld start position located adjacent said torch to close a switch when said trigger is shifted to the weld start position;    a circuit coupled to said switch to sense when said switch is closed; and    a transmitter on said wire feeder, said transmitter being coupled to said circuit and being operable to transmit a starting signal to said power source when said switch is closed whereby said power source is shifted to its on condition when said trigger is in said weld start position.    
   
   
       27 . A wire feeder as defined in  claim 26  wherein said transmitter is an RF transmitter.  
   
   
       28 . A wire feeder as defined in  claim 27  wherein said wire feeder has a voltage select device for manual adjustment to a condition corresponding to a desired arc voltage.  
   
   
       29 . A wire feeder as defined in  claim 28  including a circuit to convert said condition to a voltage level signal and a transmitter on said wire feeder to transmit said voltage level signal to said power source whereby said power source is set to said desired voltage.  
   
   
       30 . A wire feeder as defined in  claim 26  wherein said transmitter creates a signal transmitted to said power source through said input lead to said output terminal of said power source.  
   
   
       31 . A wire feeder as defined in  claim 30  wherein said wire feeder has a voltage select device for manual adjustment to a condition corresponding to a desired arc voltage.  
   
   
       32 . A wire feeder as defined in  claim 31  including a circuit to convert said condition to a voltage level signal and a transmitter on said wire feeder to transmit said voltage level signal to said power source whereby said power source is set to said desired voltage.  
   
   
       33 . A wire feeder as defined in  claim 26  wherein said wire feeder has a voltage select device for manual adjustment to a condition corresponding to a desired arc voltage.  
   
   
       34 . A wire feeder as defined in  claim 33  including a circuit to convert said condition to a voltage level signal and a transmitter on said wire feeder to transmit said voltage level signal to said power source whereby said power source is set to said desired voltage.  
   
   
       35 . A method for turning on a power source of an electric arc welder including a remotely located wire feeder connected to said power source by a power cable, said method comprising: 
 (a) starting the welding cycle of a welding process for said welder by shifting a weld starting trigger of the wire feeder to a weld start position to close a switch;    (b) sensing said starting by sensing when said switch is closed using a sensor circuit in the wire feeder;    (c) transmitting a signal from said wire feeder to said power source when said starting is sensed; and    (d) starting said power source upon receipt of said signal to direct power to said wire feeder by said cable.    
   
   
       36 . A method as defined in  claim 35  wherein said transmitted signal is RF.  
   
   
       37 . A method as defined in  claim 35  wherein said transmitted signal is by way of said cable.