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Electrical or electronic apparatus, in particular welding machine or

1. 0087 With reference to FIG 1A a circuit diagram may be observed immediately comprehensible to those skilled in the art of the control electronics of a first embodiment of a welding machine according to the invention 0088 The electronics is power supplied by a single phase mains to which it connects through phase and neutral termi nals F and N while a third terminal GND is connected to the ground ofthe mains in particular the three terminals F N and GND are part of an input interface consisting of an electrical plug SP1 0089 Mains current crosses an EMI filter against electro magnetic interferences E1 and is rectified by a first diode bridge power rectifier P1 that receives the alternate current from the filter E1 and deliver the same rectified to a capacitor C1 smoothing it Thus rectified and smoothed current is re converted in a high frequency preferably ranging from 50 to 100 KHz one by a DC AC power converter B1 for power supplying the primary ofa transformer the secondary of which is connected to an output rectifying stage having two output terminals positive O1 and negative O2 which deliver arc voltage and current In this regard although in FIG 1A is shown a single phase mains other embodiments of the machine according to the present invention may be power supplied through three phase mains by means of simple cir cuit adaptations within the reach of those skilled in the art 0090 EMI filter El tha
2. R10 and R12 greatly reduces preferably by about 400 times the rectified voltage and applies it to the input of the operational amplifier U13A Preferably the val ues of resistances chosen for the divider are very high for making a very low value of current circulate during measure ment The operational amplifier U13A amplifies the voltage across the resistor R7 of the divider of voltage the amplified voltage at the output of the operational amplifier U13A sup plies the internal LED of an optoisolator OP1 The optoiso lator OP1 has the function of galvanically insulating the mea suring circuit from the microprocessor M1 The output of the optoisolator OP1 is connected to a resistor R69 in pull up configuration and the signal present on the output terminal GROUND equal to the voltage between the output of the optoisolator OP1 and grounds is sent to a digital input ofthe microprocessor M1 that verifies its state high or low in case of a state of high signal no voltage is present between the selected supply terminal i e the terminal F or P depending on the stats of the relay K1 and the ground terminal GND in case of a state of low signal a voltage is present between the selected supply terminal and the ground terminal GND 0121 Preferably the microprocessor M1 enables detec tion of the correct or incorrect connection of the protection ground conductor by carrying out the following sequence of steps 0122 ina first step the mi
3. RFID active or passive transpon ders or tags 0105 a temperature sensor ST1 for sensing the tem perature internal to the machine 0106 a temperature sensor ST2 for sensing the tem perature external to the machine 0107 device Z5 for detecting the blood alcohol con centration ofthe operator that will be shown below with reference to FIG 7 0108 a pressure sensor Z6 for detecting the correct performance of the test through the blood alcohol con centration detecting device Z5 0109 a digital transducer Z7 for sensing the height based by way of example and not by way of limitation on the MEMS pressure sensor LPS001 D available from the ST Microelectronics company 0110 The microprocessor M1 is further provided with a first input output interface INT1 through which it is con nected to the generator F2 for controlling its generation ofthe PWM signals driving the gates of the two IGBTs I1 and 12 in particular the microprocessor M1 transmits the control sig nals to the generator F2 preferably on the basis of settings manually made by an operator or automatically made by the welding program selected by the operator on the basis of which the generator drives the two IGBTs I1 and I2 In par ticular the microprocessor M1 is capable to know the output voltage at the terminals O1 and O2 i e the arc voltage on the basis of the control signals that the same microprocessor M1 transmits to the generator F2 and of the t
4. detection of electrical quantities characteristic for the machine operation In particular the microprocessor M1 is provided with an interface collector COL1 that is connected to 0096 device 51 for sensing the correct connection of the protection ground conductor i e of the third termi nal GND to the ground ofthe mains that will be shown below with reference to FIG 6 Jul 11 2013 0097 through a first transducer VT1 the secondary ofa transformer TRO the primary of which is connected to the phase and neutral terminals F and N for sensing the mains voltage 0098 through a second transducer CT1 a temperature sensor RT1 for sensing the temperature of the power electronic components of the DC AC power converter Bl 0099 through a third transducer CT2 a current shunt resistor R8 for sensing the current delivered by the bridge P1 0100 through a fourth transducer CT3 a shunt resistor R4 for sensing the current delivered by the machine at the output terminals O1 and O2 i e the arc current 0101 aGPS or AGPS georeferenced position sensor 71 for detecting the georeferenced position of the machine 0102 a pressure sensor Z2 for sensing the pressure of the gas possibly used in the welding or cutting process e g in GMAW TIG or plasma welding 0103 a humidity sensor Z3 for sensing the humidity of the air external to the machine 0104 aradiofrequency identifier or RFID sensor 74 for detecting and reading
5. device M2 is capable to convert digital data processed starting from signals delivered by the micropro cessor M1 or retrieved from the memory of the same codec device M2 into audio signals which are then amplified by the same codec device M2 for being played by a speaker G1 connected to the latter Other embodiments of the machine according to the invention may further have the microproces sor M1 and the codec device M2 incorporated in a single processing and controlling electronic unit e g a micropro cessor having adequate processing capacity 0117 FIG 6 shows by way of example and not by way of limitation a circuit diagram immediately comprehensible to those skilled in the art of an implementation of the device S1 for sensing the correct or incorrect connection of the protec tion ground conductor which carries out the detection through a measurement of the voltage present between the phase terminal F and the ground terminal GND and the measure ment of the voltage present between the neutral terminal N and ground terminal GND With reference to FIG 6 it may be observed that the device S1 is activated by the microprocessor M1 through the two suitable input control terminals TEST ENABLE and SELECT F N and transmits the detection data to the microprocessor M1 through the output terminal GROUND such terminals TEST ENABLE SELECT F N and GROUND are connected to the microprocessor M1 through the interface collector COL1 Mo
6. from the device S1 of FIGS 1A and 6 Further embodi ments ofthe welding machine according to the invention may be also not provided with the device Z5 for detecting the blood alcohol concentration ofthe operator with the pressure sensor Z6 for sensing the correct performance of the test through the device Z5 and with the digital transducer Z7 for detecting the height 0154 By way of example and not by way of limitation FIG 1B shows a circuit diagram immediately comprehen sible to those skilled in the art of the control electronics of a second embodiment of a welding machine according to the invention that differs from the machine of FIG 1A in that the device for sensing the correct connection of the protection ground conductor consists of a current sensor S1 connected to the microprocessor M1 through the interface collector COL1 that senses the current crossing the terminal GND connected to the mains ground In particular the machine of FIG 1B further differs from that of FIG 1A because it is not provided with the device Z5 for detecting the blood alcohol concentration ofthe operator with the pressure sensor Z6 and with the digital transducer Z7 for detecting the height 0155 For both the embodiments ofthe machine according to the invention shown in FIGS 1A and 1B the microproces sor M1 may further process the signals received from the various components to which it is connected and obtain the information necessary for gener
7. geographical area selectable and automatically set table by said processing and controlling electronic means on the basis of a position of the apparatus detected in georeferenced manner which information is in a lan guage that is selectable and automatically settable by said processing and controlling electronic means on the basis of the detected position of the apparatus 27 The apparatus according to claim 16 wherein said processing and controlling electronic means is connected to further interface means comprising a display and a keypad on which interface means said processing and controlling elec tronic means is capable to display one or more information 28 The apparatus according to claim 27 wherein the appa ratus is a welding machine and in that said processing and controlling electronic means is capable to receive from said interface means data related to one or more parameters selected from the group comprising a type of material of an electrode when the apparatus is a welding machine operating according to a welding pro cess with shielded electrode or SMAW Shielded Metal Arc Welding atype of material of a wire when the apparatus is a welding machine operating according to an arc welding process with metal protected by gas or GMAW Gas Metal Arc Welding a type of a material to be welded a heat capacity of a material to be welded a rapidity of consumption of a deposited material one or more consumables 29 Th
8. the output ter minals O1 and O2 0209 Incase of stop due to over temperature the cooling fan V remains active until the temperature sensed by the sensor ST1 lowers below a minimum temperature threshold preferably equal to 20 0210 Obviously the above may be immediately applied also to the case wherein the machine is provided with more than one internal temperature sensor in this case it is suffi cient that only one of them senses an over temperature for activating the procedure just shown the machine preferably remaining stopped until all the sensors sense a temperature lower than the minimum temperature threshold 0211 With regard to the calculation of the time necessary for restoring a correct temperature within the machine as a function of the external temperature and ventilation the microprocessor M1 operates as follows 0212 As itis known the temperature T decreases from the value T even in conditions of forced ventilation according to the relationship FT Ide US 2013 0175248 Al where 0213 is room temperature and 0214 his atime constant depending on numerous factors variable most of all as functions of the operative conditions such as for instance the efficiency of forced ventilation 0215 The time constant h cannot be precisely known ma it can be temporarily set during manufacturing within the range from 100 to 800 for instance 400 On the basis of this tempo
9. the user during both the welding process and the stand by steps and US 2013 0175248 Al 0141 generating suitably modulated sounds capable to convey information useful to the operator during the welding process 0142 In particular on the basis of the signals received from the various components to which it is connected the microprocessor M1 is capable to detect in real time the opera tion conditions of the welding machine and to provide the operator with information about such conditions 0143 By way of example the microprocessor M1 is capable of 0144 sensing through the device S1 the actual connec tion of the ground conductor and consequently inform ing the operator on the presence or not of the ground connection of the machine signalling to the operator the outcome of such detection through display on the dis play DY1 and or speech messages played by the speaker G1 containing information related to the consequences due to an inadequate connection of the ground conduc tor 0145 detecting through the device Z5 and the sensor 76 a state of alcohol intoxication of the operator and consequently informing the operator about the outcome of the test through display on the display DY1 and or speech messages played by the speaker G1 such detec tion may be conditioned to the height above ground at which the operator is as detected through the transducer ZT 0146 sensing through the transformer TRO the mains vo
10. 66 current sensor preferably comprising a current shunt resistor capable to detect a current of the second ary of the second transformer preferably connected to said processing and controlling electronic means through a fourth transducer said one or more conditions of apparatus operation compris ing one or more conditions depending on one or more param eters detected by said sensing electronic means and or deter mined through processing by said processing and controlling electronic means selected from the group comprising 0067 an input voltage of the DC AC power converter 0068 a current of the primary of the second trans former and 0069 a current of the secondary of the second trans former 0070 Still according to the invention said processing and controlling electronic means may be capable to inhibit said apparatus operation upon occurrence of one or more opera tion conditions recognised on the basis of said one or more detection signals which are received 0071 The present invention relates to an electrical or elec tronic apparatus in particular an electronic welding machine or a battery charger capable to acquire data related to envi ronmental conditions status of the mains temperature humidity etc and to determine operation conditions of a process carried out by the apparatus e g a welding process On the basis of this analysis the apparatus suggests precau tions to adopt so as to optimise safet
11. D and delivers the information about correct connection of the protection ground conductor simultaneously enabling the welding machine to carry out a welding process or the information about incorrect connec tion of the protection ground conductor thus indicating the state of danger of the mains preferably providing for further US 2013 0175248 Al possible suggestions for solving the problem In particular the microprocessor M1 provide the operator with information by displaying the same on the display DY1 and or giving corresponding speech messages through the speaker G1 Preferably in the case where an incorrect connection of the protection ground conductor is detected the microprocessor M1 disables the welding process not sending the necessary control signals to the generator F2 so that the two positive and negative output terminals O1 and O2 provides for zero volt age and current 0127 In this regard the microprocessor M1 enables the detection of the connection of ground at least upon turning the welding machine on preferably the microprocessor M1 may also periodically repeat such detection e g by activating the relays K1 and K2 according to the sequence shown above upon expiry of a time interval and as soon as it detects through the shunt resistor R4 that no welding process is in progress i e as soon as the output current is zero 0128 FIG 7 shows by way of example and not by way of limitation a circuit diagram
12. G 1B shows a circuit diagram ofthe control elec tronics of a second embodiment of a welding machine according to the invention 0079 FIG 2 schematically shows a mathematical model of the welding process on the basis of which the machine of FIG 1A is capable to calculate non directly measurable parameters 0080 FIG 3 schematically shows as the model of FIG 2 interacts with acoustic playing means of the machine of FIG 1A 0081 FIG 4 schematically shows an example geometrical configuration related to one of the welding programs of the machine of FIG 1A 0082 FIG 5 schematically shows a second example geo metrical configuration related to one ofthe welding programs of the machine of FIG 1A 0083 FIG 6 shows a circuit diagram of a component shown in the circuit diagram of FIG 1A and 0084 FIG 7 shows a circuit diagram of a further compo nent connected to the circuit diagram of FIG 1A 0085 In FIGS 1A 1B 6 and 7 references also when identical to the electronic components e g diodes resistors transistors and relays do not indicate the same electronic components unless expressly stated to the contrary 0086 In particular symbols of the electronic components and values of the respective electrical quantities given in US 2013 0175248 Al FIGS 6 and 7 are examples and they have not to be intended as limiting the scope of protection of the present invention unless expressly stated to the contrary
13. ONIC APPARATUS IN PARTICULAR WELDING MACHINE OR BATTERY CHARGER 0001 The present invention relates to an electrical or elec tronic apparatus in particular an electronic welding machine with or without the addition of molten metal capable to protect the operator from risks of accident due to the use of the apparatus as well as to deliver information through speech messages concerning safety rules technical rules for correct management of the parameters of the apparatus and rules for a good result in the apparatus operation such as for instance a good result in welding In particular the welding machine according to the invention allows ina reliable versatile effec tive simple and inexpensive way that is handy for the opera tor to monitor the conditions of machine operation and to assist the operator during welding phases by delivering infor mation through sounds and speech messages which are immediately receivable interpretable and understandable The welding machine according to the invention allows to create the conditions for a working environment in which all the possible situations which may cause danger are pointed out giving to the operator suggestions for working according to procedures allowing to clearly perceive and assess the risk for the person and things that is associated with the operations to perform 0002 In the following the invention is shown mainly making reference to a welding machine However it must b
14. US 20130175248A1 a2 Patent Application Publication Pub No US 2013 0175248 1 as United States De Rosa 43 Pub Date Jul 11 2013 54 ELECTRICAL OR ELECTRONIC APPARATUS IN PARTICULAR WELDING MACHINE OR BATTERY CHARGER 75 Inventor Guglielmo De Rosa Conza Della Campania AV IT 73 Assignee Awelco Inc Production S P A 21 Appl No 13 822 506 22 PCT Filed Sep 13 2011 86 PCT 371 0D 2 4 Date PCT IT11 00316 Mar 12 2013 30 Foreign Application Priority Data Sep 13 2010 RM2010A000475 Publication Classification 51 Int CI HO2H 1 00 2006 01 B23K 9 095 2006 01 52 U S CL CPC eduk H02H 1 0007 2013 01 B23K 9 095 2013 01 henna 219 130 01 307 326 57 ABSTRACT The present invention concerns an electrical or electronic apparatus in particular welding machine or battery charger comprising processing and controlling electronic means M1 M2 connected to a sensing electronic means S1 S1 TRO VT1 R8 2 Z1 Z2 Z3 74 75 76 77 R4 CT3 ST1 ST2 D12 Q1 from which it receives one or more detection signals of one or more electrical and or physical quantities related to an apparatus operation said processing and controlling electronic means M1 M2 being capable to determine one or more conditions of apparatus operation on the basis of said one or more detection signals the
15. ans 39 The apparatus according to claim 37 wherein said one or more acoustic signalling comprise emission of at least one second sound having an amplitude depending on a reference value of said first parameter of apparatus operation and a frequency depending on a reference value of said second parameter of apparatus operation 40 The apparatus according to claim 25 wherein said one or more speech messages are in a language that is selectable and automatically settable by said processing and controlling electronic means on the basis of a position of the apparatus detected in georeferenced manner 41 The apparatus according to claim 29 wherein the DC AC power converter is of dual switch forward type and comprises two power semiconductor devices each compris ing a gate driven by a pulse width modulation or PWM Pulse Width Modulation signal generator controlled by said pro cessing and controlling electronic means dc ae a d
16. ans preferably comprising a display more pref erably a LCD and or touch screen display and a keypad more preferably incorporated into the display when it is touch screen on which interface means said processing and con trolling electronic means is preferably capable to display one or more information in a language that is more preferably selectable still more preferably automatically settable by said processing and controlling electronic means on the basis of a position even more preferably detected in georeferenced manner of the apparatus 0057 Furthermore according to the invention the appara tus may be a welding machine and said processing and con trolling electronic means may be capable to receive from said interface means data related to one or more parameters selected from the group comprising 0058 a type of material of an electrode when the appa ratus is a welding machine operating according to a welding process with shielded electrode or SMAW Shielded Metal Arc Welding 0059 atype of material of a wire when the apparatus is a welding machine operating according to an arc weld ing process with metal protected by gas or GMAW Gas Metal Arc Welding 0060 type of a material to be welded 0061 aheat capacity of a material to be welded 0062 arapidity of consumption of a deposited material 0063 one or more consumables 0064 Always according to the invention the apparatus may be a welding machine co
17. apparatus being capable to be power supplied through a plurality of terminals F N GND by a mains comprising a ground con ductor to which a ground terminal GND of said plurality of terminals F N GND is connectable the apparatus being characterised in that said sensing electronic means comprises or consists of a device S1 for sensing a connection of the ground terminal GND to the ground conductor ofthe mains d M2 G1 EEEN Patent Application Publication Jul 11 2013 Sheet 1 of 5 US 2013 0175248 Al US 2013 0175248 A1 Jul 11 2013 Sheet 2 of 5 Patent Application Publication Patent Application Publication Jul 11 2013 Sheet 3 of 5 US 2013 0175248 A1 parameters 10 la Va gt outputs ta Fig 2 parameters Fig 4 Fig 5 US 2013 0175248 Al Jul 11 2013 Sheet 4 of 5 Patent Application Publication 9 D NEZ ONT KA TEV NA LSIL cnt I 178 9 25 rd yozz z HOE ET e 13 140 N EE ANNOUD gt vein d Mp 69 1 AZI DOA a 9izsva Ix dA 9iceva za TYTN d LOTTAS 9Lzeva ra i ACI 22A Patent Application Publication Jul 11 2013 Sheet 5 of 5 US 2013 0175248 A1 ETILOMETRO OUT Fig 7 2 2K 1206 2 R8 100R 1206 GND ETIL ENABLEN US 2013 0175248 Al ELECTRICAL OR ELECTR
18. ating sounds and or messages through the codec device M2 0156 In particular the microprocessor M1 processes the received signals on the basis of a mathematical model of the welding process through which it is capable to calculate with sufficient approximation characteristic parameters not directly measurable of the same process such as for instance in a MMA machine dissipated power temperature in the welding area electrode consumption Moreover the model allows the microprocessor M1 to indirectly extrapolate fur ther statistical data such as e g an indication of the regular ity ofthe welding process a probability that slags have been incorporated a numerical indication about the whole quality ofthe process 0157 With reference to the schematic representation of FIG 2 model 10 has as input data the electrical and physical quantities related to the arc welding process i e 0158 arc current i e the output current delivered by the terminals O1 and O2 US 2013 0175248 Al 0159 arc voltage Va 1 6 the output voltage present at the terminals O1 and O2 and 0160 temperature external to the machine 0161 Further input data may be external humidity and pressure of the gas possibly used 0162 Numerous characteristic parameters related to the particular welding process in progress may represent input data for the mathematical model in particular 0163 the specific heat capacity of the material to be welded
19. ation of the user interface some of these amounts may be displayed on the display DY1 0180 The machine according to the invention may also allow the operator to select two among all the characteristic parameters ofthe welding process including those which are measured and calculated for synthesising on the basis of them a sound that is played by the speaker G1 the amplitude and frequency of which depends each on one of the two selected parameters whereby perception ofthe sound allows monitoring by the operator of the two selected parameters 0181 By way of example as shown by the schematic representation of FIG 3 if it is desired to monitor the arc current and voltage the program carried out by the micropro cessor determines a value V proportional to the delivered current and a value proportional to the arc voltage and the codec device M2 a sound is synthesise through the codec device M2 which has an amplitude depending on V and a frequency depending on V that is then played by the speaker G1 Preferably the relationship between V and the amplitude variation and the relationship between and the frequency variation of the sound synthesised is not necessarily linear in order to improve intelligibility and pleasantness of the pro duced sound 0182 The machine according to the invention may also provide for the option of superimposing to the thus synthe sised sound that is a function ofthe real time values ofth
20. atus 0034 temperature external to the apparatus and 0035 a ventilation made by at the fan 0036 Always according to the invention the apparatus may be a welding machine and said sensing electronic means may further comprise 0037 apressure sensor capable to detect a pressure of a gas used by the apparatus when it is a welding machine operating according to an arc welding process with metal protected by gas or GMAW Gas Metal Arc Weld ing or when it is a welding machine operating accord ing to an arc welding process with infusible tungsten electrode protected by inert gas or TIG Tungsten Inert Gas or when it is a welding machine operating accord ing to a plasma welding or cutting process US 2013 0175248 Al said one or more conditions of apparatus operation compris ing one or more conditions depending on one or more param eters detected by said sensing electronic means and or deter mined through processing by said processing and controlling electronic means selected from the group comprising 0038 a pressure of a gas used by the apparatus when it is a welding machine operating according to an arc welding process with metal protected by gas or GMAW Gas Metal Arc Welding or when it is a welding machine operating according to an arc welding process with infusible tungsten electrode protected by inert gas or TIG Tungsten Inert Gas or when it is a welding machine operating according to a plasma welding or cu
21. bviously both or either one of the two operative modes of the sound interface may be disabled by the operator through the keypad K1 0185 Along with on the basis of the importance level speech messages are preferably classified according to five categories informing messages functional messages train ing messages real time operative messages and attention messages 0186 Informing messages are messages related to the knowledge of the machine to the use instructions to the service centres available in the territory to their location and US 2013 0175248 Al contacts These messages are contained in an electronic cata logue that may be also browsed by the operator through the display DY1 and keypad K1 through which the operator may pass from one page to the other suitably guided by the soft ware executed by the microprocessor MI preferably pages are organised according to a logic tree structured so as to facilitate retrieval of information e g in a similar way as pages of a web site connected to each other by hyperlinks 0187 Functional messages are messages informing the operator about the status of the environmental conditions in which the machine is to operate or is operating such as for instance mains voltage temperature internal to the machine temperature of the electronic components of the electronics of the machine external temperature and humidity 0188 Training messages allow the operator to follow st
22. concentration to verifying whether the machine is used on a scaffolding In such case through the detection provided by the digital transducer Z7 the microprocessor may determine which is the height above ground of the machine e g by disabling the welding process ifthe operator does not undergo the detection of the blood alcohol concen tration and the outcome of the latter is negative 0134 Also for the detection of the blood alcohol concen tration of the operator the microprocessor M1 may enable such detection ofthe ground connection at least upon turning the welding machine on preferably the microprocessor M1 may also periodically repeat such detection e g upon expiry of a time interval and as soon as it detects through the shunt resistor R4 that no welding process is in progress 1 e as soon as the output current is zero thus avoiding that the operator may drink during short breaks during the welding process without detection by the machine 0135 The functions that the microprocessor M1 carries out further comprise 0136 adjusting the current reference signal sent to the generator F2 0137 converting the analog signals coming from the transducers and sensors to which it is connected 0138 processing such signals onthe basis ofalgorithms welding programs based on mathematical models as described below 0139 managing the user interface comprising display DY1 and keypad K1 0140 generating speech messages supporting
23. cord are hence stored the following further information 0171 thermal mode 0172 size and material of the electrode or wire 0173 arc current 0174 arc voltage 0175 geometrical size of chamfer if needed 0176 material to be welded 0177 The operator before proceeding may select in the database the information corresponding to the program that it is going to execute The machine automatically sets the weld ing parameters which may however be manually modified by the operator by acting on the display DY1 and or on the keypad K1 0178 Itis useful to still point out that the thermal model is part ofthe information associated with each specific program 0179 the basis of the selected program the micropro cessor M1 processes the model with data acquired by the sensors and transducers and those of the parameters associ ated by calculating in real time the temperature distributions in proximity with the region subjected to the process hence further data such as power dissipated by the arc the optimal arc current the optimal arc voltage Va the average tempera ture of the welding area rapidity of consumption of the elec trode or wire or deposited material advance velocity of the welding bead efficiency of the gas for machines using it a Jul 11 2013 regularity index of the welding process the thermal gradient estimated inside the machine On the basis of the choices of the operator made during customis
24. croprocessor M1 activates the relay K2 while the relay K1 is not activated whereby the phase terminal is selected consequently the mesh of the components D3 R3 R5 R7 R10 and R12 is supplied with the voltage present between the terminals and GND i e with the voltage present between the phase terminal F and the ground terminal GND of the plug SP1 of FIG 1A and the microprocessor M1 veri fies the presence or the absence of such voltage on the basis of the signal present on the output terminal GROUND of the device S1 0123 ina second step the microprocessor M1 deacti vates the relay K2 so as to discharge the measuring circuit downstream of the mesh comprising the resistive voltage divider 0124 ina third step the microprocessor M1 simulta neously activates the two relays K1 and K2 whereby the mesh of components D3 R3 R5 R7 R10 and R12 is supplied with the voltage present between the terminals N and GND i e with the voltage present between the neutral terminal N and the ground terminal GND of the plug SP1 of FIG 1A and the microprocessor M1 veri fies the presence or the absence of such voltage on the basis of the signal present on the output terminal GROUND of the device S1 0125 ina fourth and final step the microprocessor M1 deactivates both the relays K1 and K2 0126 Atthe end of such sequence the microprocessor M1 processes the detection data i e the values of the signal at the output terminal GROUN
25. cy identifier or RFID sensor capable to detect and read RFID active or passive tran sponders or tags and 0027 at least one photodiode preferably infrared emit ting photodiode more preferably controlled by said pro cessing and controlling electronic means and at least one phototransistor preferably sensitive to infrared for detecting at least one infrared radiation received from said at least one photodiode said at least one photodiode and said at least one phototransistor being capable to detect a ventilation made by at least one fan for cooling the apparatus preferably controlled by said processing and controlling electronic means said one or more conditions of apparatus operation compris ing one or more conditions depending on one or more param eters detected by said sensing electronic means and or deter mined through processing by said processing and controlling electronic means selected from the group comprising 0028 a voltage of mains 0029 a network impedance 0030 an output current delivered by the apparatus pref erably a welding arc current when the apparatus is a welding machine operating according to an arc welding process 0031 an output voltage of the apparatus preferably a welding arc voltage when the apparatus is a welding machine operating according to an arc welding process 0032 a temperature of one or more electronic compo nents of the apparatus 0033 a temperature inside the appar
26. d by gas or GMAW Gas Metal Arc Welding or when it is a welding machine operating according to an arc welding process with infusible tungsten electrode protected by inert gas or TIG Tungsten Inert Gas or when it is a welding machine operating according to a plasma welding or cutting process an average temperature of a welding area an arc power when the apparatus is a welding machine operating according to an arc welding process a regularity index of the welding process according to which the apparatus operates a type of material of an electrode when the apparatus is a welding machine operating according to a welding pro cess with shielded electrode or SMAW Shielded Metal Arc Welding arapidity of consumption ofan electrode when the welding machine operates according to a welding process with shielded electrode or SMAW Shielded Metal Arc Welding a type of material of a wire when the apparatus is a welding machine operating according to an arc welding process with metal protected by gas or GMAW Gas Metal Arc Welding a rapidity of consumption of a wire when the apparatus is a welding machine operating according to an arc welding process with metal protected by gas or GMAW Gas Metal Arc Welding a type of a material to be welded a heat capacity of a material to be welded a rapidity of consumption of a deposited material and US 2013 0175248 Al one or more consumables identified through one or more RFID activ
27. e consider that almost all the innovative technical features shown for the welding machine are applicable to any electri cal or electronic apparatus e g a battery charger a drill or a lawn mower in particular to a household appliance e g a washing machine for monitoring the conditions of appara tus or household appliance operation still remaining within the scope of the present invention 0003 It is known that various welding processes currently exist such as welding with shielded electrode called SMAW Shielded Metal Arc Welding or also MMA Manual Metal Arc arc welding with metal protected by gas called GMAW Gas Metal Arc Welding or also depending on the type of gas that is used MIG Metal Inert Gas or MAG Metal Active Gas arc welding with infusible tungsten electrode protected by inert gas called TIG Tungsten Inert Gas and plasma welding the technique of which similar to the TIG one is also used for cutting metal 0004 For making the various welding processes a plural ity of electrical and electronic welding machines are known equipped with devices for detecting controlling and manag ing the parameters relevant to the various welding processes Such machines are normally provided with a user interface that may be of variable complexity in most simple cases adjusting knobs and indications through led devices only may be present while more advanced systems may have graphical displays also with touch scr
28. e apparatus according to claim 16 wherein the appa ratus is a welding machine and in that it comprises a first diode bridge power rectifier that receives a power supply alternate current through an EMI filter and that delivers the rectified current to a DC AC power converter controlled by Jul 11 2013 said processing and controlling electronic means for supply ing power to a primary of a second transformer a secondary of the second transformer being connected through a second diode bridge power rectifier diode bridge power rectifier and at least one current levelling inductor to two output terminals of the apparatus said sensing electronic means comprising one or more electronic components selected from the group comprising a current sensor capable to detect a current of the primary of the second transformer a current shunt resistor capable to detect a current of the primary of the second transformer connected to said processing and controlling electronic means through a third transducer whereby the current shunt resistor operates as a current sensor acurrent sensor capable to detect a current of the secondary of the second transformer and a current shunt resistor capable to detect a current of the secondary of the second transformer connected to said processing and controlling electronic means through a fourth transducer whereby the current shunt resistor operates as a current sensor said one or more conditions of appara
29. e or passive tags 24 The apparatus according to claim 16 wherein said processing and controlling electronic means are further con nected to acoustic playing means through which said process ing and controlling electronic means is capable to control a play of one or more acoustic signalling related to said one or more conditions of apparatus operation 25 The apparatus according to claim 24 wherein said one or more acoustic signalling comprise one or more speech messages stored in memory means to which said processing and controlling electronic means is connected 26 The apparatus according to claim 24 wherein said processing and controlling electronic means controls a speech reproduction through said acoustic playing means of speech messages and or speech messages in a language that is selectable and auto matically settable by said processing and controlling electronic means on the basis of a position of the appa ratus detected in georeferenced manner and or at least one portion of a user manual of the apparatus and or at least one portion of a user manual of the apparatus in a language that is selectable and automatically settable by said processing and controlling electronic means on the basis of a position of the apparatus detected in georef erenced manner and or information related to service and or sale centres present in an geographical area and or information related to service and or sale centres present in an
30. e two selected parameters also a sound of reference corresponding to the sound that would be produced if the same welding process would be carried out with the optimal values of the two selected parameters In such a way the operator has the opportunity to have a direct and immediate feedback from the welding machine for adjusting the performance modes of the welding process so as to optimise it 0183 As already said the interface operates through two distinct operative modes selectable by the operator i e the previously described speech synthesis and delivering speech messages In the latter case the sound interface is capable to communicate a series of helping messages to the operator ensuring information useful to the correct advance of the process The functions of speech synthesis and the one of generation of speech messages are managed by the micropro cessor M1 with the aid of the codec device M2 shown in FIG 1 0184 Messages are preferably classified according to three importance levels as requested for the operator from a minimum level 1 to a maximum level 3 The operator may select the desired level so that the sound interface has a more or less invasive behaviour with regard to the operative environment by selecting the level 1 all the messages are transmitted by selecting the level 2 only important and emer gency messages are transmitted by selecting the level 3 only emergency messages are transmitted O
31. eens 0005 A first possible problem resulting from the use of welding machines is due to the fact that the operators using such machines outside their own place of work that is pro tected from electrical risks are exposed to the risks that the hosting electrical system possibly has and which are unknown 0006 The conventional welding machines are always pro vided with a paper booklet of instructions in which the related safety rules and the precautions to be adopted during the use are also listed Some of these rules and precautions are extremely important for operator protection Jul 11 2013 0007 However both skilled and not skilled welding operators neglect the study of the safety rules contained in the instruction booklet This entails that companies are obliged to make training courses on the use of the welding machines stressing the safety rules Also the welding machines due to their wide diffusion are used not only by specifically trained operators but also by untrained operators Lack of preparation of the operators is even more pronounced in the hobby field 0008 Moreover some works such as that of making welding from a scaffolding may be dangerous for the shock effect that the user may experience In fact some subjects may feel the electrical shock effect even for very low voltages in any case lower than the dangerous ones of 50 volt ac and 120 volt de In a welding machine the probability of getting in c
32. ep by step a series of instructions for training purposes for executing the welding process according to optimal criteria Training is scheduled on a diversified series of types of weld ing processes which may change depending on the material and form of the objects to be welded 0189 Real time operative messages provide the operator with operative information during the welding process such as for instance 0190 inadequacy of the connection of ground and or reaching of a minimum value of the mains voltage and or reaching of a maximum value of the mains voltage if importance level 1 is enabled signalling is accompanied by information of consequences that the use of the machine in these conditions may imply 0191 the condition of sobriety or not of the operator 0192 the height above ground at which the machine is if importance level 1 is enabled signalling is accompa nied by information related to safety rules which must be met by the operator 0193 excessively high mains impedance if importance level 1 is enabled speech signalling is also accompanied by the suggestion about which electrode or wire can be possibly used with the available mains impedance in fact the value of the mains impedance conditions the maximum value of current that may be delivered and hence the type of the possible electrode or wire to use 0194 the expediency of modifying the welding param eters 0195 the expediency of changing the p
33. f the apparatus 0052 Always according to the invention said processing and controlling electronic means may control a speech repro duction through said acoustic playing means of 0053 speech messages in a language that is preferably selectable more preferably automatically settable by said processing and controlling electronic means on the basis of a position still more preferably detected in georeferenced manner of the apparatus and or 0054 at least one portion of a user manual of the appa ratus in a language that is preferably selectable more preferably automatically settable by said processing and controlling electronic means on the basis of a position still more preferably detected in georeferenced manner of the apparatus and or 0055 information related to service and or sale centres present in an geographical area in a language that is preferably selectable more preferably automatically settable by said processing and controlling electronic means on the basis of a position still more preferably detected in georeferenced manner of the apparatus said geographical area being preferably selectable more preferably automatically settable by said processing and controlling electronic means on the basis of a position still more preferably detected in georeferenced manner of the apparatus 0056 Still according to the invention said processing and controlling electronic means may be connected to further interface me
34. g machine operating according to an arc welding process an output voltage of the apparatus an output welding arc voltage of the apparatus when the apparatus is a welding machine operating according to an arc welding process a temperature of one or more electronic components of the apparatus a temperature inside the apparatus a temperature external to the apparatus and a ventilation made by the fan 23 The apparatus according to claim 16 wherein the appa ratus is a welding machine and in that said sensing electronic means further comprises a pressure sensor capable to detect a pressure of a gas used by the apparatus when it is a welding machine operating according to an arc welding process with metal pro tected by gas or GMAW Gas Metal Arc Welding or when it is a welding machine operating according to an arc welding process with infusible tungsten electrode protected by inert gas or TIG Tungsten Inert Gas or when it is a welding machine operating according to a plasma welding or cutting process said one or more conditions of apparatus operation compris ing one or more conditions depending on one or more param eters detected by said sensing electronic means and or deter mined through processing by said processing and controlling electronic means selected from the group comprising a pressure of a gas used by the apparatus when it is a welding machine operating according to an arc welding process with metal protecte
35. immediately comprehensible to those skilled in the art of an implementation of the device Z5 for detecting the blood alcohol concentration of the operator preferably based on the sensor device TGS822 available from the FIGARO USA Inc company indicated in FIG 7 with the reference L1 The device Z5 is activated by the microproces sor M1 through the control input terminal ETIL ENABLE and transmits the detection data to the microprocessor M1 through the output terminal ETILOMETRO OUT such ter minals are connected to the microprocessor M1 through the interface collector COLI 0129 The circuit of FIG 7 is used by the microprocessor MI for reading variations of voltage across the resistor R1 connected between pins 4 6 of the sensor L1 and the circuit ground This voltage present at the output terminal ETILO METRO OUT when alcohol vapours are absent is equal to about 1 95 volt and increases proportionally to the concen tration of alcohol vapours up to about 4 5 volt for the maxi mum alcohol concentration Since for carrying out precise measurements it is necessary that the sensor L1 is stabilised at the operating temperature the sensor L1 internally has a resistor allowing its heating Moreover the voltage across the resistor R1 once raised due to the presence of alcohol vapours rapidly decreases when the one who undergoes the test stop to blow the microprocessor M1 must hence detect the maximum peak of the voltage present at the ou
36. ing electronic means with at least one signal of detection of said at least one voltage coming from said input interface means said processing and controlling electronic means being capable to activate the device for sensing a connection of the ground terminal to the ground conductor of the mains through said input interface means said input interface means being preferably connected to all the terminals of said plurality of terminals more preferably so as to be capable to select through switching means controlled by said processing and controlling electronic means and to send to said measuring electronic means a voltage between a terminal of said plurality of terminals different from the ground terminal and the ground terminal said measuring electronic means preferably comprising rec tifying means connected to voltage divider means in turn connected to amplifier means said input interface means being connected to said rectifying means and said amplifier means being connected to said output interface means said output interface means preferably comprising an optoisolator 0015 Furthermore according to the invention the device for sensing a connection of the ground terminal to the ground conductor of the mains may comprise a ground current sensor capable to sense a current flowing along the ground terminal 0016 Always according to the invention said sensing electronic means may further comprise a device for sensing a blood alcohol c
37. is capable to control a play of one or more acoustic signalling related to said one or more conditions of apparatus operation said one or more acoustic signalling being preferably depending on said one or more detection signals said one or more acoustic signalling more preferably comprising emission of at least one first sound having an amplitude depending on a first parameter of appa ratus operation and a frequency depending on a second parameter of apparatus operation said first and second parameters being still more preferably selectable by an opera tor through interface means connected to said processing and controlling electronic means said one or more acoustic sig nalling even more preferably comprising emission of at least one second sound having an amplitude depending on a refer ence value of said first parameter of apparatus operation and a frequency depending on a reference value of said second parameter of apparatus operation 0051 Furthermore according to the invention said one or more acoustic signalling may comprise one or more speech messages preferably stored in memory means to which said Jul 11 2013 processing and controlling electronic means is connected said one or more speech messages being in a language that is preferably selectable more preferably automatically settable by said processing and controlling electronic means on the basis of a position still more preferably detected in georef erenced manner o
38. lasma welding reaching of values higher than respective maximum thresholds of compressor pressure and of air humidity for which fault probability of the welding machine increases 0204 If the operator selects the operation mode of the speech messages it is preferably automatically set the impor tance level 3 in which only such attention messages being connected to events requiring absolute attention from the operator are played 0205 The machine preferably manages internal over tem perature situations as follows 0206 The internal temperature of the machine is sensed by the sensor ST1 in a critical point ofthe same machine with which two attention temperature thresholds are associated a warning threshold T and a maximum threshold T with lt preferably Tuta C 0207 Ifthe temperature sensed by the sensor ST1 exceeds the warning threshold T a warning is emitted to the operator to whom it is suggested to end the welding process as soon as possible for allowing a correct cooling of the welding machine and in order to allow welding to be suspended according to the most suitable modes 0208 In the case where the welding process continuous and the temperature sensed by the sensor ST1 exceeds the maximum threshold T a warning sound is emitted and within a short time interval for instance equal to 30 seconds the microprocessor M1 deactivates the generator F2 inter rupting the delivery of current and voltage at
39. led in the art can make variations and changes without so departing from the related scope of protection as defined by the follow ing claims 1 15 canceled 16 Electrical or electronic apparatus in particular welding machine or battery charger comprising processing and con trolling electronic means connected to a sensing electronic means from which it receives one or more detection signals of one or more electrical and or physical quantities related to an apparatus operation said processing and controlling elec tronic means being capable to determine one or more condi tions of apparatus operation on the basis of said one or more detection signals the apparatus being capable to be power supplied through a plurality of terminals by a mains compris ing a ground conductor to which a ground terminal of said plurality of terminals is connectable wherein said sensing electronic means comprises or consists of a device for sensing a connection of the ground terminal to the ground conductor ofthe mains 17 The apparatus according to claim 16 wherein said plurality of terminals consists of along with the ground ter minal a phase terminal and of un neutral terminal whereby the apparatus is capable to be power supplied by a single phase mains 18 The apparatus according to claim 16 wherein the device for sensing a connection of the ground terminal to the ground conductor of the mains comprises input interface means connected to the g
40. ltage and signalling to the operator a possible incor rect voltage by possibly accompanying such signalling with speech messages played by the speaker G1 con taining information related to the consequences due to an inadequate mains voltage 0147 sensing through the transformer TRO the mains voltage and signalling to the operator a possible incor rect voltage by possibly accompanying such signalling with speech messages played by the speaker G1 con taining information related to the consequences due to an inadequate mains voltage 0148 detecting an excessively high mains impedance e g due to inadequacy of the system or to use of a not correctly sized extension cord in particular this is made by comparing the mains voltage sensed through the transformer TRO in two different conditions of out put current in turn sensed through the shunt resistor R4 respectively in an unloaded way i e output current zero and for high values of output current e g not lower than 50 Ampere preferably not lower than 80 Ampere more preferably not lower than 100 Ampere when comparison shows a significant decrease e g not lower than 5 of the unloaded mains voltage of the mains voltage for high values of output current the micropro cessor M1 is capable to signal and or inform the operator about the high value of the mains impedance 0149 sensing through the sensor ST2 the external temperature and signalling and or informing the o
41. more electrical and or physical quantities related to an appa ratus operation said processing and controlling electronic means being capable to determine one or more conditions of apparatus operation on the basis of said one or more detection signals the apparatus being capable to be power supplied through a plurality of terminals by a mains comprising a ground conductor to which a ground terminal of said plurality ofterminals is connectable the apparatus being characterised in that said sensing electronic means comprises or consists of a device for sensing a connection ofthe ground terminal to the ground conductor of the mains 0013 Always according to the invention said plurality of terminals may consist of along with the ground terminal a phase terminal and of un neutral terminal whereby the appa ratus is capable to be power supplied by a single phase mains 0014 Still according to the invention the device for sens ing a connection of the ground terminal to the ground con ductor of the mains may comprise input interface means connected to the ground terminal and to at least one other terminal of said plurality of terminals said input interface means being further connected to measuring electronic means capable to measure at least one voltage coming from said input interface means said measuring electronic means US 2013 0175248 Al being in turn connected to output interface means capable to provide said processing and controll
42. mprising a first diode bridge power rectifier that receives a power supply alternate current preferably through an EMI filter more preferably a passive US 2013 0175248 Al one and that delivers the rectified current preferably through at least one voltage levelling capacitor ad a DC AC power converter controlled by said processing and controlling elec tronic means for supplying power preferably at high fre quency more preferably with frequency ranging from 50 to 100 KHz to a primary of a second transformer a secondary of the second transformer being connected to preferably through a second diode bridge power rectifier diode bridge power rectifier and at least one current levelling inductor to two output terminals of the apparatus the DC AC power converter being preferably of dual switch forward type and more preferably comprising two power semiconductor devices preferably two IGBTs each comprising a gate pref erably driven by a pulse width modulation or PWM Pulse Width Modulation signal generator controlled by said pro cessing and controlling electronic means said sensing elec tronic means comprising one or more electronic components selected from the group comprising 0065 un current sensor preferably comprising a cur rent shunt resistor capable to detect a current of the primary of the second transformer preferably connected to said processing and controlling electronic means through a third transducer and 00
43. nics could monitor and provide for information and or disable the apparatus operation on con ditions of inefficient ground on the state of sobriety of the operator on the mains voltage on an excessively high mains impedance e g due to inadequacy ofthe system or to the use ofan undersized extension cord on the internal temperature Jul 11 2013 of the apparatus or household appliance on the efficiency of a cooling ventilation as well as providing use instructions and information on service and selling centres further select ing the language on the basis ofthe georeferenced position of the apparatus or household appliance 0219 Moreover the device for detecting the blood alcohol concentration of the operator along with the pressure sensor for detecting the correct execution of the test through the device for detecting the blood alcohol concentration and possibly together the transducer for detecting height may be also inserted in an electrical or electronic apparatus in par ticular a welding machine also independently from the pres ence of one or more ofthe other devices and detecting sensors illustrated above in particular independently from the pres ence of the device for detecting the correct connection of the protection ground conductor to the mains ground 0220 The preferred embodiments have been above described and some modifications ofthis invention have been suggested but it should be understood that those skil
44. o said processing and controlling electronic means through a third transducer a temperature sensor capable to detect a temperature inside the apparatus atemperature sensor capable to detect a temperature exter nal to the apparatus a GPS or AGPS georeferenced position sensor capable to detect a georeferenced position of the apparatus ahumidity sensor capable to detect a humidity of air exter nal to the apparatus a radiofrequency identifier or RFID sensor capable to detect and read RFID active or passive transponders or tags and at least one photodiode controlled by said processing and controlling electronic means and at least one pho totransistor for detecting at least one radiation received from said at least one photodiode said at least one pho todiode and said at least one phototransistor being capable to detect a ventilation made by at least one fan for cooling the apparatus controlled by said processing and controlling electronic means said one or more conditions of apparatus operation compris ing one or more conditions depending on one or more param eters detected by said sensing electronic means and or deter mined through processing by said processing and controlling electronic means selected from the group comprising Jul 11 2013 a voltage of mains a network impedance an output current delivered by the apparatus an output welding arc current delivered by the apparatus when the apparatus is a weldin
45. on that is proportional according to specifi cations provided by the manufacturer of the sensor L1 to the maximum value detected at the output terminal ETILO METRO OUT The microprocessor M1 provides for the out come of the test through information displayed on the display DY1 and or by providing corresponding speech messages through the speaker G1 preferably by indicating that it is possible to proceed with the welding process if the detected blood alcohol concentration is lower than a maximum thresh old e g 0 3 mg l and instead by indicating that it is not possible to proceed if the detected blood alcohol concentra tion is higher than the maximum threshold and simulta neously disabling the welding process 0131 The microprocessor M1 is capable to determine when the operator is actually carrying out the test through the pressure sensor Z6 located in correspondence of the funnel In fact by analysing the data coming from the sensor Z6 the microprocessor M1 determines the maximum value of the voltage at the output terminal ETILOMETRO OUT only when it recognises that the operator is blowing within the funnel 0132 The microprocessor M1 may identify the operator through the sensor Z4 of RFID tags prior to the test so as to enable the welding process only for those operators who have undergone the test 0133 Preferably the microprocessor M1 may condition the need for preliminarily carrying out the detection of the blood alcohol
46. oncentration preferably comprising input interface means through which said processing and control ling electronic means being capable to activate the device for sensing a blood alcohol concentration connected to sensing means for sensing an alcohol vapour concentration in turn connected to output interface means capable to provide said processing and controlling electronic means with at least one detection signal said sensing electronic means preferably further comprising a pressure sensor capable to provide said processing and controlling electronic means with at least one pressure detection signal on the basis of which said process ing and controlling electronic means is capable to determine when said at least one detection signal coming from the device for sensing a blood alcohol concentration is signifi cant 0017 Still according to the invention said sensing elec tronic means may further comprise sensing means for sensing a height above ground at which the apparatus is said process ing and controlling electronic means preferably activating the device for sensing a blood alcohol concentration when the height sensed by said sensing means for sensing a height above ground is higher or not lower than a threshold value 0018 Furthermore according to the invention said sens ing electronic means may further comprise one or more elec tronic components selected from the group comprising 0019 a voltage sensor connected to two power s
47. ontact for example with the electrode is very high thus the effect although not dangerous occurs and may cause a temporary slip that represents a real danger if the operator is on a scaffolding above ground The shock effect is even more dangerous if the operator is under the influence of alcohol 0009 Finally achievement of a good welding depends on a number of factors among which the operator s preparation the welding machine characteristics materials to be added as well as adjustments of the parameters of the machine for the type of material to be added 0010 In this context the solution proposed according to the present invention is introduced 0011 It is therefore an object of the present invention to allow in a reliable versatile effective simple and inexpen sive way that is handy for the operator to monitor the condi tions of operation of an electrical or electronic apparatus in particular a welding machine or a battery charger and to assist the operator during the operation carried out by the apparatus for instance a welding operation by delivering information which are immediately receivable and under standable 0012 Itis specific subject matter of this invention an elec trical or electronic apparatus in particular welding machine or battery charger comprising processing and controlling electronic means connected to a sensing electronic means from which it receives one or more detection signals of one or
48. ossible electrode or wire 0196 the temperature inside the machine 0197 pressure and humidity which are two parameters which in the TIG or plasma for both welding and cut ting welding machines are essential for quality of the welding process in this case the speech messages may also guide the operator to the correct value of pressure to use 0198 efficiency of ventilation 0199 suggested consumables and or settings of the cor rect welding parameters for instance in case of wire welding if the coil is provided with identification TAG this is read by the detector Z4 and the machine proceeds to modify current voltage velocity of the wire and pulses It informs the operator about the gas to use and the best way to obtain a good welding 0200 Attention messages are messages which are gener ated upon occurrence of exception events or emergencies and which require absolute attention such as Jul 11 2013 0201 reaching of a critical temperature inside the machine and if importance level 1 is enabled the time needed for restoring depending on external temperature and ventilation is communicated as well as it will be described below 0202 necessity of pre heating the piece to be welded if external temperature is below a predetermined mini mum threshold preferably equal to 4 C in fact in limit cases the temperature gradient may cause damages to the pieces to be welded 0203 in case of TIG or p
49. ovide said processing and controlling electronic means with at least one detection signal 21 The apparatus according to claim 20 wherein said sensing electronic means further comprises sensing means for sensing a height above ground at which the apparatus is said processing and controlling electronic means 22 The apparatus according to claim 16 wherein said sensing electronic means further comprises one or more elec tronic components selected from the group comprising a voltage sensor connected to two power supply input terminals of the apparatus a first transformer the primary of which is connected to two input terminals of the apparatus in turn connected to two lines of a mains and the secondary of which is connected to said processing and controlling electronic means through a first transducer whereby the first transformer is capable to operate as a voltage sensor a temperature sensor capable to sense a temperature of one or more electronic components of the apparatus con nected to said processing and controlling electronic means through a second transducer a current sensor capable to sense an output current deliv ered by the apparatus a current sensor capable to sense an output welding arc current delivered by the apparatus when the apparatus is a welding machine operating according to an arc weld ing process a current shunt resistor capable to sense an output current delivered by the apparatus that is connected t
50. pera tor of possible necessity of preheating the piece to be welded 0150 detecting through activation of the photodiode D12 and the consequent detection by the phototransistor Q1 the efficiency of the ventilation carried out by the V in fact the photodiode D12 and the phototransistor Q1 allow to detect whether the flow of the ventilation is obstructed or not since the photodiode D12 transmits Jul 11 2013 against a possible obstacle present in front of the outlet duct of the fan V and the microprocessor M1 interprets possible absence or weakness of the infrared signal received by the phototransistor Q1 as a presence of an obstacle obstructing the ventilation flow 0151 identifying through the detector Z4 one or more consumables provided with TAG e g an electrode for SMAW welding or a wire coil for GMAW welding and signalling and or informing the operator about inad equacy of the consumable 0152 selecting the language in which display informa tion on the display DY1 and or providing speech mes sages through the speaker G1 as well as selecting infor mation about the location of service and selling centres e g ofaccessories and consumables on the basis ofthe detection through detector Z1 of the georeferenced position of the machine 0153 Other embodiments of the welding machine accord ing to the invention may also have devices for sensing the correct connection ofthe protection ground conductor differ ent
51. preferably expressed with a simple numerical classification e g 1 for very high heat capacity such as for instance in case of light sheet metal 2 for high heat capacity such as for instance in case of heavy sheet metals 3 for medium heat capacity such as for instance in case of light massive objects and 4 for low heat capacity such as for instance in case of heavy massive objects 0164 the type of the possible electrode for SMAW welding or of the possible wire for GMAW welding preferably categorised on the basis of cross section and alloy 0165 the type of material to be welded preferably cat egorised 0166 the type of the same process SMAW GMAW GTAW etc 0167 the position of pieces horizontal vertical upside down 0168 size of the elements classified in four categories 1 for light sheet metal 2 for heavy light sheet 3 for light massive objects 4 for heavy massive objects 0169 All these parameters as well as the same thermal model are characteristics of the particular welding process that is intended to be carried out For this reason a particular welding program containing both the thermal model and the characteristic parameters is associated with each type The program hence constitutes the single record of a database in which stored numerous operative types are stored of which FIGS 4 and 5 represent their examples 0170 In the single re
52. ransformation ratio of the transformer TR1 Through the collector COL1 the microprocessor M1 could be further capable to further receive from the generator F2 data related to the operation of the latter 0111 Moreover the microprocessor M1 is provided with a second input output interface INT2 through which it is connected to 0112 a fan V for cooling the machine of which it con trols the operation 0113 an infrared emitter photodiode D12 of which it controls the emission and an infrared sensitive pho totransistor Q1 for sensing the infrared radiation US 2013 0175248 Al received from the photodiode D12 Still the micropro cessor M1 is further connected to 0114 through a third input output interface INT3 a graphical display DY1 preferably a LCD onto which depending on the operation state of the machine infor mation related to the parameters set by the user and or the values of some variables of interest are shown and 0115 through a fourth input output interface INT4 a keypad K1 possibly incorporated in a touch screen type display DY1 through which an operator may select an operation mode of the welding machine 0116 Finally through the first input output interface INT1 the microprocessor M1 is connected to preferably through a serial connection a codec audio encoder decoder device M2 for managing sounds and speech messages pro vided with a mass storage memory storing speech messages which codec
53. rary value through relationship 1 the microprocessor M1 is capable to estimate the time necessary to temperature T for lowering down to the minimum threshold Also by periodically sampling the temperature T after the stop of delivery of current and voltage by the machine the micropro cessor M1 is capable to determine with greater precision the value of the time constant h in those determined operative conditions whereby the estimation of the time for restoring can be progressively more accurate giving in short times about 1 minute the correct estimation 0216 Also in this case the procedure for estimating the time for restoring may be immediately adapted to the case where the machine is provided with more than one internal temperature sensor the longest estimated time for restoring is theonethat is communicated as the time remaining to the end ofthe machine stop Of course the value of the time constant his always updated with the last estimated value upon occur rence of a stop for over temperature 0217 The preferred embodiments of the machine accord ing to the invention are further capable to suggest the most suitable procedures for executing operations capable to remove other causes of inhibition ofthe welding process By way of example and not by way of limitation in a MMA machine the current absorbed from the mains is a function of the electrode diameter and of the current setting e g an electrode of 3 25 mm of diame
54. re in particular the device S1 allows the microprocessor M1 to verify the pres ence of voltage between the phase terminal F connected to the input terminal F of FIG 6 and the ground terminal GND connected to the input terminal GND of FIG 6 and the absence of voltage between the neutral terminal N connected to the input terminal F of FIG 6 and the ground terminal GND 0118 The device S1 of FIG 6 comprises two relays a relay K1 that is a switching relay having the task of selecting the terminal i e either phase or neutral one of which the voltage with respect to ground is to be measured and a relay K2 having the task of enabling the detection by power sup plying through the mesh formed by the diode D3 and resis tors R3 R5 R7 R10 and R12 a downstream measuring circuit When it is not activated the switching relay K1 is in a closed position corresponding to the selection of the phase terminal while when it is activated it is in an open position corresponding to the selection of the neutral terminal 0119 Through the two input terminal signals TEST ENABLE and SELECT P N the microprocessor M1 is capable to activate respectively the two relays K2 and K1 Jul 11 2013 0120 When the relay K2 is activated the diode D3 recti fies the mains ac voltage coming from terminal F or P depending on the state of the relay K1 making the only positive half wave pass The voltage divider formed by resis tors R3 R5 R7
55. round terminal and to at least one other terminal of said plurality of terminals said input inter face means being further connected to measuring electronic means capable to measure at least one voltage coming from said input interface means said measuring electronic means being in turn connected to output interface means capable to provide said processing and controlling electronic means with at least one signal of detection of said at least one voltage coming from said input interface means said processing and controlling electronic means being capable to activate the device for sensing a connection of the ground terminal to the ground conductor of the mains through said input interface means 19 The apparatus according to claim 16 wherein the device for sensing a connection of the ground terminal to the ground conductor of the mains comprises a ground current sensor capable to sense a current flowing along the ground terminal US 2013 0175248 Al 12 20 The apparatus according to claim 16 wherein said sensing electronic means further comprises a device for sens ing a blood alcohol concentration comprising input interface means through which said processing and controlling elec tronic means is capable to activate the device for sensing a blood alcohol concentration said input interface means being connected to sensing means for sensing an alcohol vapour concentration which is in turn connected to output interface means capable to pr
56. s according to claim 18 wherein said output interface means comprises an optoisolator 34 The apparatus according to claim 20 wherein said sensing electronic means further comprises a pressure sensor capable to provide said processing and controlling electronic means with at least one pressure detection signal on the basis of which said processing and controlling electronic means is capable to determine when said at least one detection signal coming from the device for sensing a blood alcohol concen tration is significant 35 The apparatus according to claim 21 wherein said processing and controlling electronic means activates the device for sensing a blood alcohol concentration when the height sensed by said sensing means for sensing a height above ground is higher or not lower than a threshold value US 2013 0175248 Al Jul 11 2013 14 36 The apparatus according to claim 24 wherein said one or more acoustic signalling depend on said one or more detec tion signals 37 The apparatus according to claim 36 wherein said one or more acoustic signalling comprise emission of at least one first sound having an amplitude depending on a first param eter of apparatus operation and a frequency depending on a second parameter of apparatus operation 38 The apparatus according to claim 37 wherein said first and second parameters are selectable by an operator through interface means connected to said processing and controlling electronic me
57. t is preferably a passive filter limits electromagnetic disturbance produced by the machine and led towards the mains 0091 The DC AC power converter B1 is preferably ofthe dual switch forward type and comprises two IGBTs 11 and 12 the gates of which are driven by a pulse width modulation or PWM Pulse Width Modulation signal generator F2 for creating a pulse voltage on the primary of the transformer TR1 that is unipolar also thanks to the presence of the two blocking diodes D1 and D2 0092 The transformer TR1 besides to lowering the volt age level down to the value needed for welding ensures a galvanic insulation of the welding output section con nected to the output terminals O1 and O2 from the mains section 0093 The output rectifying stage comprises a second diode bridge power rectifier P2 that receives the current delivered by the secondary of the transformer TR1 and an inductor L2 connected between the rectifier P2 and the posi tive output terminal O1 so as to rectify and smooth the output voltage of the transformer TRI 0094 The type of conversion adopted in the machine of FIG 1A is purely a not limiting example i e it does not characterise the present invention 0095 The welding machine is controlled by a micropro cessor M1 provided with a memory not shown in FIG 1A that is connected to the power electronics and to a plurality of transducers and sensors from which it receives a plurality of
58. ter needs a current absorbed from the mains of about 15 Amperes If the electrical system id undersized or used by interposing an extension cord with unsuitable cable besides the fact that the voltage supplying the machine is reduced and hence the same welding is not permitted the electrical system can also be damaged The preferred embodiments of the machine according to the invention constantly monitoring the mains impedance as seen above by comparing the mains voltage sensed through the transformer TRO in two different conditions of output current in turn sensed through the shunt resistor R4 are capable to recognise the occurrence of a situation of exces sively high mains impedance and the consequent risk of dam aging the electrical system and they warn the operator on how to eliminate the risk e g by limiting the maximum diameter that may be used for that electrical system 0218 Itis further immediate to apply the control electron ics of the welding machine according to the invention to any electrical or electronic apparatus e g a battery charger a drill or a lawn mower in particular to a household appliance e g a washing machine for monitoring the conditions of opera tion of the apparatus or household appliance and providing users with information through synthesised speech and or sounds messages as shown for the welding machine accord ing to the invention By way of example but not by way of limitation the electro
59. ties and in case of a welding machine a higher sensitivity to the flash blindness produced during the welding process 0074 Furthermore in some embodiments ofthe apparatus according to the invention in particular of the welding machine the apparatus constantly monitors the process that it is intended to carry out e g the welding process through the characteristic parameters thereof such as for instance in case of a welding machine voltage current arc length velocity gas amount etc Such parameters if not directly measurable are estimated on the basis of the results of the real time processing of one or more mathematical models In such case the operator is assisted also with speech messages which may suggest the correction of parameters for achieving a good result e g a good welding 0075 Assistance through speech messages is preferably extended to play of the instruction manual as well as to all those information dedicated to identify service centres and consumable material supply centres in the area where the apparatus has been sold and or is used 0076 The present invention will be now described by way of illustration and not by way of limitation according to its preferred embodiments by particularly referring to the Fig ures of the enclosed drawings in which 0077 FIG 1A shows a circuit diagram of the control elec tronics ofa first embodiment of a welding machine according to the invention 0078 FI
60. tput termi nal ETILOMETRO OUT 0130 The microprocessor M1 enables the detection ofthe blood alcohol concentration of the operator through the con trol input terminal ETIL ENABLE that activates the transis tor Q3 and through this supplies the heating resistor of the sensor L1 When the temperature of the sensor L1 reaches the operating temperature the voltage across the resistor R1 reaches a constant stabilised value equal to 1 95 V Once the microprocessor M1 recognises the onset of the operation conditions 1 6 the reaching of the operation temperature in the sensor L1 through analysis ofthe data received from the output terminal ETILOMETRO OUT the microprocessor M1 provides the operator with instructions about how to undergo the blood alcohol concentration test such instruc tions may be provided by displaying the same on the display DY1 and or providing for corresponding speech messages through the speaker G1 At this point the operator must blow in a small funnel coupled to the sensor of the device Z5 and the microprocessor determines the maximum value of the Jul 11 2013 voltage at the output terminal ETILOMETRO OUT the microprocessor M1 recognises that the operator is sober when such maximum value remains equal to the constant stabilised value i e 1 95 V otherwise if such maximum value is higher the microprocessor M1 recognises that the operator has taken alcohol and determines his her blood alco hol concentrati
61. tting process 0039 an average temperature of a welding area 0040 an arc power when the apparatus is a welding machine operating according to an arc welding process 0041 a regularity index of the welding process accord ing to which the apparatus operates 0042 a type of material of an electrode when the appa ratus is a welding machine operating according to a welding process with shielded electrode or SMAW Shielded Metal Arc Welding 0043 a rapidity of consumption of an electrode when the welding machine operates according to a welding process with shielded electrode or SMAW Shielded Metal Arc Welding 0044 atype of material of a wire when the apparatus is a welding machine operating according to an arc weld ing process with metal protected by gas or GMAW Gas Metal Arc Welding 0045 a rapidity of consumption of a wire when the apparatus is a welding machine operating according to an arc welding process with metal protected by gas or GMAW Gas Metal Arc Welding 0046 a type of a material to be welded 0047 a heat capacity of a material to be welded 0048 arapidity of consumption ofa deposited material and 0049 one or more consumables identified through one or more RFID active or passive tags 0050 Still according to the invention said processing and controlling electronic means may be further connected to acoustic playing means through which said processing and controlling electronic means
62. tus operation compris ing one or more conditions depending on one or more param eters detected by said sensing electronic means and or deter mined through processing by said processing and controlling electronic means selected from the group comprising an input voltage of the DC AC power converter a current of the primary of the second transformer and a current of the secondary of the second transformer 30 The apparatus according to claim 16 wherein said processing and controlling electronic means is capable to inhibit said apparatus operation upon occurrence of one or more operation conditions recognised on the basis of said one or more detection signals which are received 31 The apparatus according to claim 18 wherein said input interface means is connected to all the terminals of said plurality of terminals so as to be capable to select through switching means controlled by said processing and control ling electronic means and to send to said measuring elec tronic means a voltage between a terminal of said plurality of terminals different from the ground terminal and the ground terminal 32 The apparatus according to claim 18 wherein said measuring electronic means comprises rectifying means con nected to voltage divider means in turn connected to amplifier means said input interface means being connected to said rectifying means and said amplifier means being connected to said output interface means 33 The apparatu
63. upply input terminals of the apparatus the sensor being pref erably a first transformer the primary of which is con nected to two input terminals of the apparatus in turn connected to two lines ofa mains preferably a phase line and a neutral line of a single phase mains or two lines of a three phase mains and the secondary of which is con nected to said processing and controlling electronic means preferably through a first transducer Jul 11 2013 0020 atemperature sensor capable to sense a tempera ture of one or more electronic components of the appa ratus preferably connected to said processing and con trolling electronic means through a second transducer 0021 acurrent sensor capable to sense an output cur rent delivered by the apparatus preferably a welding arc current when the apparatus is a welding machine oper ating according to an arc welding process the current sensor preferably comprising a current shunt resistor more preferably connected to said processing and con trolling electronic means through a third transducer 0022 atemperature sensor capable to detect a tempera ture inside the apparatus 0023 atemperature sensor capable to detect a tempera ture external to the apparatus 0024 a GPS or AGPS georeferenced position sensor capable to detect a georeferenced position of the appa ratus 0025 a humidity sensor capable to detect a humidity of air external to the apparatus 0026 a radiofrequen
64. y conditions In particu lar the apparatus may bea welding machine dedicated to any welding process in particular a SMAW or MMA GMAW or MIG or MAG TIG or even plasma including its appli cation for cutting besides welding process 0072 In particular cases for example a mains voltage beyond the operative limits or absence of a connection to a ground line the apparatus may preferably inhibit the process that it is intended to perform e g the welding process more preferably giving communication thereof through both dis play and speech message In the case where it is possible to carry out operations capable to remove causes of inhibition the apparatus preferably suggests the most adequate proce dure Jul 11 2013 0073 Moreover some embodiments of the apparatus according to the invention allows detection ofa possible state of alcohol intoxication of the operator and the consequent inhibition of the process that is intended to carry out e g the welding process preferably but non limitedly in the case where a condition of use on a scaffolding is also detected In such way the apparatus according to the invention allows to eliminate all the dangers related to the use of the same appa ratus when the operator has taken alcohol dangers due to an underestimation of the danger with consequent increase of therisk an inferior capacity of concentration an alteration of the distance perception an alteration of visual capaci

Electrical or electronic apparatus, in particular welding machine or

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