Patents by Inventor Jake Zwayer
Jake Zwayer has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11020813Abstract: Systems, methods, and apparatus to reduce cast in a welding wire are disclosed. Example systems to reduce cast in a welding wire include a wire advancement roller configured to advance welding wire from a welding wire supply toward a welding torch; and a wire straightener configured to reduce cast in the welding wire by applying heat to the welding wire between the welding wire supply and the welding torch.Type: GrantFiled: September 13, 2017Date of Patent: June 1, 2021Assignee: Illinois Tool Works Inc.Inventors: Jonathan A. Will, Jake Zwayer
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Publication number: 20210094116Abstract: Systems, methods, and apparatus to provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.Type: ApplicationFiled: September 8, 2020Publication date: April 1, 2021Inventors: James Lee Uecker, Jake Zwayer
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Patent number: 10926349Abstract: Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding torch includes: a welding assembly comprising: a first contact tip configured to conduct welding current to a consumable electrode; and a second contact tip configured to conduct preheating current to the consumable electrode; a neck having a bend, the neck configured to hold the welding assembly and to deliver the consumable electrode to the welding assembly; a torch body configured to hold the neck opposite the welding assembly; and a torch mounting assembly; wherein the welding assembly, the neck, the bend, the torch body, and the torch mounting assembly are dimensioned such that the welding torch provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch having a single contact tip.Type: GrantFiled: June 11, 2018Date of Patent: February 23, 2021Assignee: Illinois Tool Works Inc.Inventors: Dennis Roland Sigl, James Lee Uecker, Jake Zwayer
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Patent number: 10870164Abstract: A contact tip assembly with a preheating tip comprises a welding-type power source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding-type electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.Type: GrantFiled: May 16, 2017Date of Patent: December 22, 2020Assignee: Illinois Tool Works Inc.Inventors: James Lee Uecker, Jake Zwayer, Christopher Hsu
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Patent number: 10766092Abstract: Systems, methods, and apparatus to provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.Type: GrantFiled: April 18, 2017Date of Patent: September 8, 2020Assignee: Illinois Tool Works Inc.Inventors: James Lee Uecker, Jake Zwayer
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Publication number: 20200254555Abstract: Methods and apparatus to determine heat input to a weld are disclosed. An example welding-type power supply includes a power converter to convert input power to output welding-type power, and a controller configured to: during a welding-type operation, calculate average instantaneous power values of the welding-type operation for discrete, non-overlapping time periods by multiplying voltage measurements and corresponding current measurements; identify an end of the welding-type operation; determine a duration of the welding-type operation; calculate a total average instantaneous power of the welding-type operation based on the average instantaneous power values for the time periods and the duration of the welding-type operation; and determine whether an acceptable range of the welding-type operation is exceeded based on the total average instantaneous power and the duration of the welding-type operation.Type: ApplicationFiled: April 28, 2020Publication date: August 13, 2020Inventors: Christopher Hsu, Jake Zwayer
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Publication number: 20200198044Abstract: An example contact tip for a welding torch includes: a first body section having a first diameter and exterior threads, the first body section having channels extending longitudinally along an exterior surface of the first body section to permit gas flow from a first end of the contact tip to a second end of the contact tip through the channels; a first bore portion having a first inner diameter; and a second bore portion having a second inner diameter configured to contact an electrode wire traveling through the second bore portion, the first inner diameter being larger than the second inner diameter.Type: ApplicationFiled: December 19, 2019Publication date: June 25, 2020Inventors: James Uecker, Jake Zwayer
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Publication number: 20200189020Abstract: Apparatus and methods are provided for an engine driven welding-type power system that includes an engine to drive an electric generator to provide a first power output, and a removable welder having an energy storage device to provide a second power output. The system includes a housing having a dock to store a removable welder. While stored within the dock, the energy storage device is recharged by the first power output. Once removed from the dock, the removable welder is configured to operate independently of the power system.Type: ApplicationFiled: December 13, 2019Publication date: June 18, 2020Inventors: Jake Zwayer, Ben Froland
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Patent number: 10675699Abstract: A contact tip assembly with a preheating tip comprises a welding power source configured to provide welding current to a welding circuit, the welding circuit comprising a welding electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.Type: GrantFiled: November 4, 2016Date of Patent: June 9, 2020Assignee: Illinois Tool Works Inc.Inventors: Christopher Hsu, Dennis Sigl, Jake Zwayer, James Lee Uecker, Jon Michael Patterson
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Patent number: 10632557Abstract: Methods and apparatus to determine heat input to a weld are disclosed. An example welding-type power supply includes a power converter to convert input power to output welding-type power, and a controller configured to: during a welding-type operation, calculate average instantaneous power values of the welding-type operation for discrete, non-overlapping time periods by multiplying voltage measurements and corresponding current measurements; identify an end of the welding-type operation; determine a duration of the welding-type operation; calculate a total average instantaneous power of the welding-type operation based on the average instantaneous power values for the time periods and the duration of the welding-type operation; and output a first value representative of the total average instantaneous power and a second value representative of the duration of the welding-type operation.Type: GrantFiled: March 16, 2017Date of Patent: April 28, 2020Assignee: Illinois Tool Works Inc.Inventors: Christopher Hsu, Jake Zwayer
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Publication number: 20200101553Abstract: Apparatus and methods are provided for a welding-type power system that includes an engine configured to drive an electric generator to provide a first power output. An energy storage device to provide a second power output. A controller is configured to receive one or more control signals to provide a total power output to at least one of a welding-type output or an auxiliary type output, determine proportional values for the first power output and the second power output that add up to the total power output based on a power demand signal that indicates a contribution of the first power output and the second power output, control the engine to adjust speed based on the first power output value, and control a connection from the energy storage device to provide the second power output to the welding-type output based on the second power output value.Type: ApplicationFiled: September 11, 2019Publication date: April 2, 2020Inventor: Jake Zwayer
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Publication number: 20200089467Abstract: Welding helmets and methods to provide audio feedback in a welding helmet are disclosed. An example welding helmet includes: an audio device attached to the helmet, the audio device configured to output audio to the user wearing the helmet; communication circuitry configured to: receive first audio information from at least one of a personal audio device, a weld management system, a weld training system, or an audio communication system, wherein the speaker is configured to output first audio based on the first audio information; and receive second audio information from another one of the weld management system, the weld training system, or the audio communication system, the speaker configured to output second audio based on the received second audio information; and audio processing circuitry configured to interrupt playback of the first audio in response to receiving the audio message to play the second audio based on the second audio information.Type: ApplicationFiled: September 13, 2019Publication date: March 19, 2020Inventor: Jake Zwayer
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Publication number: 20200070274Abstract: Submerged arc welding torches and systems to resistively preheat electrode wire are disclosed. A disclosed example submerged arc welding torch includes: a first contact tip configured to transfer weld current and preheating current to the wire; a second contact tip configured to conduct the preheating current to the wire; an air-cooled first conductive body portion configured to receive the weld current and to conduct the weld current and the preheating current to the first contact tip; an air-cooled second conductive body portion configured to receive the preheating current and to conduct the preheating current to the second contact tip; and an insulator coupled between the first and second conductive body portions.Type: ApplicationFiled: August 30, 2019Publication date: March 5, 2020Inventors: Zakary Stapp, Jake Zwayer, Aniruddha Bhide, Valarie Schwartz
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Patent number: 10464157Abstract: A contact tip assembly with a preheating tip comprises a welding power source configured to provide welding current to a welding circuit, the welding circuit comprising a welding electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.Type: GrantFiled: November 4, 2016Date of Patent: November 5, 2019Assignee: Illinois Tool Works Inc.Inventors: Christopher Hsu, Dennis Sigl, Jake Zwayer, James Lee Uecker, Jon Michael Patterson
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Publication number: 20190030633Abstract: Systems and methods for inductance compensation in a welding-type system include a reel configured to wind a welding-type cable to reduce a first portion of the welding-type cable extending from the reel, and to unwind to increase the first portion of the welding-type cable extending from the reel, wherein a second portion of the welding-type cable is at least partially wound around the reel when stored. A controller determines a first length of the first portion of the welding-type cable, calculates a first inductance of the first portion of welding-type cable extending from the reel based on the first length, determines a second length of the second portion of the welding-type cable, calculates a second inductance of the second portion of welding-type cable wound around the reel based on the second length, and calculates a cable inductance of the welding-type cable based on the first inductance and the second inductance.Type: ApplicationFiled: July 25, 2017Publication date: January 31, 2019Inventor: Jake Zwayer
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Publication number: 20180333798Abstract: A contact tip assembly with a preheating tip comprises a welding-type power source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding-type electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.Type: ApplicationFiled: May 16, 2017Publication date: November 22, 2018Inventors: James Lee Uecker, Jake Zwayer, Christopher Hsu
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Publication number: 20180297141Abstract: Systems, methods, and apparatus to provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.Type: ApplicationFiled: April 18, 2017Publication date: October 18, 2018Inventors: James Lee Uecker, Jake Zwayer
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Publication number: 20180264578Abstract: Methods and apparatus to determine heat input to a weld are disclosed. An example welding-type power supply includes a power converter to convert input power to output welding-type power, and a controller configured to: during a welding-type operation, calculate average instantaneous power values of the welding-type operation for discrete, non-overlapping time periods by multiplying voltage measurements and corresponding current measurements; identify an end of the welding-type operation; determine a duration of the welding-type operation; calculate a total average instantaneous power of the welding-type operation based on the average instantaneous power values for the time periods and the duration of the welding-type operation; and output a first value representative of the total average instantaneous power and a second value representative of the duration of the welding-type operation.Type: ApplicationFiled: March 16, 2017Publication date: September 20, 2018Inventors: Christopher Hsu, Jake Zwayer
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Publication number: 20180099346Abstract: An example welding-type system includes: a welding-type power source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the welding-type electrode via a second contact tip of the welding torch; a switching circuit configured to control a current flow between the welding-type power source and the first contact tip; and a preheat control circuit configured to control the switching circuit to: selectively direct current from the welding-type power source to the second contact tip; and selectively divert current from the electrode preheating circuit to the first contact tipType: ApplicationFiled: September 29, 2017Publication date: April 12, 2018Inventors: Jake Zwayer, James Lee Uecker, Quinn William Schartner
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Publication number: 20170225255Abstract: A contact tip assembly with a preheating tip comprises a welding-type power source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the electrode via a second contact tip of the welding torch; and a preheat controller to: monitor a voltage drop across a second portion of the electrode; adjust at least one of the welding-type current or the preheating current based on the voltage drop, the second portion of the electrode comprising at least part of the first portion of the electrode; and control the preheating current based on a hydrogen reduction goal and based on stored parameters associated with a type of the electrode, a chemistry of the electrode, or a wire size.Type: ApplicationFiled: April 26, 2017Publication date: August 10, 2017Inventors: Jake Zwayer, Steven Barhorst, James Lee Uecker, Christopher Hsu, Dennis Sigl, Jon Michael Patterson