Square D Company

Schneider Automation Gmbh

Larry A Dew

Paul Robert Buda

Timothy E Miller

Jonathan H Bailey

Thomas R Creech

William B Davison

Robert M Slazinski

Jackie Laverne Winn

William B Davidson

Gene Steifelmeyer

Todd Charles Wheaton

An online monitor that can be permanently attached to a device to be monitored continuously monitors a set of analog signals and initiates data capture over a window of time when a user programmable set of conditions is satisfied. The online monitor includes a digital signal processing unit, a modular, interchangeable, analog signal conditioning base unit that can be tailored to the specific requirements of the process to be monitored and a modular, interchangeable, communication interface unit. The interface unit permits the digital signal processing unit to exchange data with external equipment such as network computers via a number of industry standard communication fieldbus protocols. The online monitor provides the capability to define the trigger condition under which data capture is initiated by comparing a user defined signal to a function of the instantaneous value of another signal or constant. Data captured is stored indefinitely in internally battery backed memory and the instant at which data capture is initiated is determined accurately via a time tagging function, so the data can be retrieved at a later time.

On line monitor for a control device

A field bus network of input and output devices is coupled to a control system through an I/O interface module, regardless of their data structures. The I/O interface module is coupled to the control systemthrough a serial communication port. Local input and output devices are coupled to the interface I/O module through a local I/O interface and networked input and output devices are coupled to the interface I/O module through a field bus communication adapter. A different adapter is required for each type of field bus protocol. The interface I/O module includes a microprocessor based device to generate and control the various interactions between the local devices, networked devices, and the controllsystem and also to provide for a visual and status display of the fieldbus and local I/O data local.

Control I/O module having the ability to interchange bus protocols for

A weld controller maintains an internal dynamic model of load impedance, which tracks normal impedance variations that occur as the weld tooling degrades. The weld controller contains a weld process monitor function that tests an estimated load impedance of a weld schedule presently under execution against an internal dynamic model and generates events when characteristics of the estimated load impedance of the present weld falls outside an operator definable band, indicating a problem with the workpiece presently being welded. The weld controller further includes the capability to accept a static model of the load impedance that is used as the reference impedance for the weld control and tooling. The weld controller also includes means to declare an event when characteristics of the dynamic model differ from the static model by an operator-defined amount. The weld controller allows a distinction to be made between a short-term difference in load impedance, generally indicative of a weld process variation and the long-term difference in load impedance, generally indicative of tooling degradation. This provides for tighter controls of weld process variations than could previously be achieved, coupled with an indication of incipient tooling faults.

Process monitor for a weld controller

An operator interface unit for monitoring and controlling controllers coupled to a communications network has a common database that is accessible across the network, regardless of each controllers data structure. The operator interface unit provides an apparatus for displaying, storing, and editing data obtained from the network. Data from each controller can be accessed by the unit based upon the individual controller's data structure and type through embedded objects resident in the interface unit's operating system and program. The data can then be displayed, edited, and stored by any data entry device that is capable of executing the operator interface unit's program.

Operator interface unit for monitoring and controlling devices having

A communications network is used to couple weld controllers and different operator interface units together, regardless of their data structures. An arbitration system provides a means for one operator interface unit to communicate to a selected weld controller at a given period of time. The operator interface units have one of three modes of operation. These include database master, primary master, and secondary master. During setup of the communications network, the master devices are assigned a physical address that defines the its type and priority within the network. The database master is the only device which can automatically download data to a weld controller. It has the highest priority as a network arbiter. The primary master will act as the network abitrator in the absence of a database master. A secondary master must listen for an access grant from the current network arbiter, before initiating a message packet on the network. When no database or primary device exists on a network, the secondary device with the highest priority, as defined by its address during startup, assumes the role of network arbitrator.

Arbitration method for a communication network

A communications network has an operator interface system for monitoring and controlling controllers utilizing any known control strategy. A common database is accessible across the communication network of controllers regardless of each controllers dissimilar data structure. The operator interface provides an apparatus for displaying, storing, and editing data obtained from the network. Data from each controller can be accessed by a master device based upon the controller's individual data structure and type through embedded objects resident in the master device's operating system and program. The data can then be displayed, edited, and stored by any data entry device that is capable of executing the master's program.

Common database system for a communication system

A weld controller is coupled to a communications network which has an operator interface unit for monitoring and controlling the weld controller and other weld controllers on the network. A time of day clock provides a chronological reference to tag weld current and voltage data and other data when it occurs for storage in its memory which is also accessible by the operator interface unit for storing in said system database. A memo pad in the weld controller is also accessible to the network for storing data for diagnostic purposes, said data including faults, events, and other operational data. The data can then be displayed, edited, and stored by the operator interface's program.

Diagnostic system for a weld controller

A weld control system, supplied by a polyphase voltage source, consists of an isolation contactor supplying power to separate single phase weld controllers. The single phase weld control systems have their separate power modules combined into a single power module assembly for more efficient cooling and electrical interfacing. The single power module consists of a semiconductor switch for each phase of the polyphase voltage source and a single chiller plate for mounting and cooling the switches. The chiller plate functions as a heat sink and is machined to create a series of channels that become coupled together to form a continuous tube having a single input and a single output for a coolant liquid. A SCR pair, housed in a single package in a back-to-back configuration having an isolated base construction. The base has good thermal conductivity between the heat generating semiconductors in the package and the base. This allows the SCR packages to be mounted onto the single chiller plate and still maintain the necessary voltage isolation between each phase voltage. The isolation contactor is directly coupled to the separate power modules.

Multiple single phase weld control systems coupled to a polyphase power

A weld controller is coupled to a communications network which has an operator interface unit for monitoring and controlling the weld controller and other weld controllers on the network. A common database in the operator interface unit is accessible across the communication network by the weld controller regardless of the data structure of the database. The weld controller can use the database to obtain different weld schedules, duplicate its own weld schedule to provide for easy replacement, and as a data storage for its operating parameters and values. The weld controller has a dual communications port that allows for a variety of operator interface configurations. Data from weld controller can be accessed by the operator interface controller based upon the weld controller's individual data structure and type through embedded objects resident in the operator interface's operating system and program. The data can then be displayed, edited, and stored by any data entry device that is capable of executing the operator interface's program.

Weld controller system for coupling to a common database system on a

A weld control system, supplied by a polyphase voltage source, consists of multiple and separate single phase weld controllers. The single phase weld control systems have their separate power modules combined into a single power module assembly for more efficient cooling and electrical interfacing. The single power module consists of a semiconductor switch for each phase of the polyphase voltage source and a single chiller plate for mounting and cooling the switches. The chiller plate functions as a heat sink and is machined to create a series of channels that become coupled together to form a continuous tube having a single input and a single output for a coolant liquid. A SCR pair, housed in a single package in a back-to-back configuration having an isolated base construction. The base has good thermal conductivity between the heat generating semiconductors in the package and the base. This allows the SCR packages to be mounted onto the single chiller plate and still maintain the necessary voltage isolation between each phase voltage.

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Durham, NC, United States of America

Larry A Dew