System for welding

Abstract

A welding system comprises a plurality of welders and a server. Each welder includes one or more processors and one or more sensors. The one or more sensors are configured to measure weld data. The weld data includes data related to one or more operating parameters of the welder that are configured to control an ongoing weld operation of the welder. The welding system comprises a server in communication with the one or more processors to receive the weld data. The server is configured to process the weld data and communicate the processed weld data to the one or more processors. If the weld data does not meet predetermined criteria, the one or more processors are configured to modify the ongoing weld operation of the welder.

What is claimed: 
     
         1 . A welding system comprising:
 a plurality of welders, each welder including one or more processors and one or more sensors, the one or more sensors configured to measure weld data,   wherein the weld data includes data related to one or more operating parameters of the welder that are configured to control an ongoing weld operation of the welder;   a server in communication with the one or more processors to receive the weld data, the server being configured to process the weld data and communicate the processed weld data to the one or more processors,   wherein, if the weld data does not meet predetermined criteria, the one or more processors are configured to modify the ongoing weld operation of the welder.   
     
     
         2 . The welding system according to  claim 1 , wherein the server is a cloud server, and
 further comprising a plurality of communication devices configured to receive the weld data from the one or more processors and transmit the weld data to the cloud server, and   wherein the plurality of communication devices are also configured to receive the processed weld data from the cloud server and transmit the processed weld data to the one or more processors.   
     
     
         3 . The welding system according to  claim 1 , wherein the welding system is configured to measure, record, track, and analyze data regarding inspection activities and/or is configured to process data from an inspection system so as to provide quality control and/or inspection control of welding. 
     
     
         4 . The welding system according to  claim 1 , wherein the welder including a supply of weld material and a weld supply motor assembly that moves the weld material to the welder;
 wherein the one or more sensors are configured to measure a parameter of the supply of weld material; and   wherein the one or more processors are configured to control the speed of the weld supply motor assembly based on the measured parameter of the supply of weld material.   
     
     
         5 . The welding system according to  claim 4 , wherein the motor assembly comprises a motor and a feed wheel operatively connected to the motor. 
     
     
         6 . The welding system according to  claim 5 , wherein the motor assembly comprises a pinch roller configured to push on a weld wire to bring the weld wire in contact with the feed wheel so that a rotation of the feed wheel results in a movement of the weld wire. 
     
     
         7 . The welding system according to  claim 4 , wherein the feed wheel is configured to rotationally engage the wire to move the weld wire. 
     
     
         8 . The welding system according to  claim 1 , wherein the welder comprises an orbital welder. 
     
     
         9 . The welding system according to  claim 8 , wherein the orbital welder includes a clockwise (CW) and counterclockwise (CCW) welder. 
     
     
         10 . The welding system according to  claim 1 , wherein the weld data further includes travel speed data of the welder. 
     
     
         11 . The welding system according to  claim 10 , wherein the server is configured to further receive and process the travel speed data, and
 wherein the one or more processors are configured to receive the processed travel speed data and modify the ongoing weld operation of the welder.   
     
     
         12 . The welding system according to  claim 1 , wherein the weld data comprises voltage data, current data, speed data, or any proper combination thereof. 
     
     
         13 . The welding system according to  claim 12 , wherein the voltage data includes a lead voltage applied to a weld wire. 
     
     
         14 . The welding system according to  claim 12 , the current data includes a lead current applied to a weld wire. 
     
     
         15 . The welding system according to  claim 12 , wherein, if the current data in the welder is high, the one or more processors are configured to either slow down a speed of the welder or control a position of a weld torch in the welder. 
     
     
         16 . The welding system according to  claim 12 , wherein the speed data includes a lead wire speed of a weld wire. 
     
     
         17 . The welding system of  claim 1 , wherein the server is configured to process the weld data in real-time. 
     
     
         18 . The welding system according to  claim 1 , wherein the welding system is configured to provide real-time inspection and quality control of the weld operation of the one or more of the plurality of welders based on the weld data. 
     
     
         19 . The welding system according to  claim 1 , wherein the welding system is configured to provide real-time monitoring the weld operation of the one or more of the plurality of welders. 
     
     
         20 . The welding system according to  claim 1 , wherein the welding system is configured to process the weld data from one or more of the plurality of welders simultaneously. 
     
     
         21 . The welding system according to  claim 1 , wherein the predetermined criteria includes a predetermined threshold.