Method and Apparatus for Monitoring Weld Cell

Abstract

A method and apparatus for monitoring weld cell and related activity is disclosed. The activity is sensed using a variety of sensors, and reported to the controller, or to a remote location.

Listing of all claims: 
     
         1 . A welding system that includes a weld cell related task tracking sensor operatively connected to a welding system controller, whereby the sensor tracks a related task, and wherein the sensor includes a transmitter disposed to transmit information indicative of at least one of the wire on a feeder, operator safety information, correcting operator mistakes, pre weld activity and post weld activity. 
     
     
         2 . The system of  claim 1 , wherein the transmitter is an RF transmitter disposed to transmit information indicative of the activity tracked. 
     
     
         3 . The system of  claim 2 , further comprising a network connection connected to the controller, wherein the controller includes a network interface disposed to provide the transmitted information over the network. 
     
     
         4 . The system of  claim 3 , wherein the transmitted information provided over the network includes time-related data. 
     
     
         5 . The system of  claim 1 , wherein the transmitted information is indicative of at least one of the arc being on, the gun being on, time spent grinding, time spent sanding, time spent loading, time spent waiting for a temperature, and time spent fitting up. 
     
     
         6 . The system of  claim 1 , further comprising at least a second weld cell activity tracking sensor operatively connected to the welding system controller. 
     
     
         7 . A system for tracking weld cell related tasks, comprising:
 a first sensor disposed to be responsive to at least a first weld cell related task, wherein the first sensor senses related tasks associated with at least one of changing the wire on a feeder, operator safety information, correcting operator mistakes, pre weld activity and post weld activity;   a transmitter, connected to the first sensor, and disposed to transmit information indicative of the at least a first weld cell related task; and   a receiver, disposed to receive the transmitted information.   
     
     
         8 . The system of  claim 7 , wherein the transmitter is an RF transmitter. 
     
     
         9 . The system of  claim 8 , further comprising an internet gateway responsive to the RF transmitter, and disposed to provide the transmitted information over the internet. 
     
     
         10 . The system of  claim 9 , wherein the transmitted information provided by the gateway includes time-related data. 
     
     
         11 . The system of  claim 9 , wherein the transmitted information is indicative of at least one of the arc being on, the gun being on, time spent grinding, time spent sanding, time spent loading, time spent waiting for a temperature, and time spent fitting up. 
     
     
         12 . The system of  claim 7 , further comprising:
 a second sensor disposed to be responsive to at least a second weld cell activity; and   a second transmitter, connected to the second sensor, and disposed to transmit information indicative of the at least a second weld cell activity;   wherein the receiver is further disposed to receive the transmitted information indicative of the at least a second weld cell activity.   
     
     
         13 . The system of  claim 12 , further comprising:
 a third sensor disposed to be responsive to at least a third weld cell activity; and   a third transmitter, connected to the third sensor, and disposed to transmit information indicative of the at least a third weld cell activity;   wherein the receiver is further disposed to receive the transmitted information indicative of the at least a third weld cell activity.   
     
     
         14 . The system of  claim 1 , further comprising a wire feeder connected to the welding system controller, wherein the transmitted information is indicative of at least a weight of wire on the wire feeder. 
     
     
         15 . The system of  claim 1 , wherein the transmitted information is indicative of at least operator fume exposure. 
     
     
         16 . The system of  claim 1 , wherein the transmitted information is indicative of at least one of gouging, grinding, compensating, hammering, bending, prying, chipping, and sanding. 
     
     
         17 . The system of  claim 1 , wherein the transmitted information is indicative of at least one of fitting, loading, preheating, spatter removal, post temperature, and correcting operator mistakes 
     
     
         18 . The system of  claim 7 , further comprising a wire feeder, and wherein the first sensor is a weight sensor mounted on the wire feeder to sense the weight of wire on the wire feeder, and further wherein the transmitted information is indicative of at least a weight of wire on the wire feeder. 
     
     
         19 . The system of  claim 7 , wherein the first sensor is a fume sensor, and wherein the transmitted information is indicative of at least operator fume exposure. 
     
     
         20 . The system of  claim 7 , wherein the transmitted information is indicative of at least one of fitting, loading, preheating, spatter removal, post temperature, and correcting operator mistakes