FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
COMPLETE SPECIFICATION (See section 10 and rule 13)
1. TITLE OF THE INVENTION:
"System for Data Capturing, Monitoring and Review of Arc Welding"
2. APPLICANT:
(a) NAME: Larsen & Toubro Limited
(b) NATIONALITY: Indian Company registered under the
provisions of the Companies Act-1956.
(c) ADDRESS: Larsen & Toubro Limited
L&T House, Ballard Estate, MUMBAI-400001, Maharashtra State, INDIA

3. PREAMBLE TO THE DESCRIPTION:
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

A System for Data Capturing, Monitoring and Review of Arc Welding
Field of invention
The present invention relates to an electronic data capturing, monitoring and review system, and more particularly, to a system for digitally capturing, monitoring, displaying, transferring and storage of real time weld data from one welding station to anywhere in a manufacturing shop / network.
Background of the invention
In manufacturing and fabrication industries, welding is the most critical and crucial process. At the same time, manufacturing of such critical process plant equipments for power plants, fertilizers and petro-carbon refineries needs high degree of quality.
A Japanese patent JP11048340A discloses a device for controlling welding equipment and processing data as per pre-recorded values. Another Japanese patent JP2010110782Adiscloses a device which measures welding voltage, current and compares them with first set of readings and determines the success/failure of the welding.
Further, a US Patent No.US5571431A discloses a device which sends parameters from computer to welding equipment and receives back actual values. It compares both values and highlights if the difference is out of tolerance.
Furthermore, a US Patent No. US6441342 discloses a device which monitors the waveforms for different combination of welding parameters, compares the results with pre-defined characteristics and generates the required characteristic of welding process.

However, the devices/systems disclosed in the above-mentioned patents do not provide data logging and recording of all welding future reference and analysis.
Objects of the invention
An object of the present invention is to provide a system for measurement, monitoring, alarming and recording of all welding parameters locally as well as centrally for future reference and analysis.
Another object of the present invention is to provide a system which enable plant supervisors to monitor the welding parameters on real time monitoring system and refer the record of the same at anytime and anywhere within the network range.
Summary of the invention
Accordingly, the present invention provides an automatic system for data capturing, remote monitoring and review of arc welding, the system comprising:
a welding means for welding components, the welding means powered by a power source;
a holding means for holding the components to be welded thereon;
a data logger panel/digital processor for processing welding speed data received from the holding means, signals from a temperature sensor unit and a temperature control panel, welding voltage data from the welding power source and welding current data from a current sensor,
wherein, the processed data is displayed on a screen of the data logger panel/digital processor which is transmitted using Wi-Fi antenna to a Wi-Fi router and the Wi-Fi router in turn records the processed data in a memory device of a central server data bank for analysis and troubleshooting, thereby providing completely automatic system for data capturing, storage and transfer without manual intervention,

Typically, wherein the processed data is stored in a data bank for fetching and reviewing with ease for future use.
Typically, wherein the data from the data logger panel/digital processor is transmitted by multiple accessing facilities using one of the latest technologies such as Wi-Fi, LAN, and Serial communication.
Typically, wherein the audio visual-alarming system for pre-defined parameter ranges is provided by the monitoring system.
Typically, wherein trending and reviewing software is provided for plotting and displaying the recorded data.
Typically, "/herein the monitoring and analyzing of the welding data results in increased productivity.
Brief description of drawings
Figure 1 shows a system for data capturing, monitoring and review of arc welding, in accordance with the present invention;
Figure 2 shows a system for manual arc welding in accordance with an embodiment of the present invention;
Figure 3 shows a flowchart for the operation of the system of figure 1, in accordance with the present invention;
Figure 4 shows a flowchart for the operation of the system at user end, in accordance with the present invention; and

Figure 5 show a graph of processed data received from the system for review and analysis.
Detailed description of the invention
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with the prior art techniques and approaches are overcome by the present invention as described below in the preferred embodiment.
The present invention provides an automatic system for measurement, remote monitoring, alarming and recording of all welding parameters locally as well as centrally for future reference and analysis. The system enables plant supervisors to monitor the welding parameters on real time monitoring system and refer the record of the same at anytime and anywhere within the network range.
The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the figure. These reference numbers are shown in bracket in the following description.
Referring now to figure 1, there is shown a system for data capturing, monitoring and review of arc welding, in accordance with the present invention. Specifically, the figure 1 shows the system (100) for semi automated welding (SAW)/automated welding. The system (100) includes a welding means (10), a power source (20) for the welding means (10), a holding means (30) and a data logger panel/digital processor (40).
The welding means (10) is powered by the welding power source (20) for welding a component (50). In an embodiment, the welding means (10) is a welding torch. The welding torch is designed for holding or feeding a filler wire/ electrode to

produce an arc when getting contacted with joining metal. The welding torch is used for both automatic and manual welding.
The component (50), for example, the metal component to be welded is rolled over the holding means (30) during the process of welding. In an embodiment, the holding means is a turning roller. The tuning roller is used to rotate the two joining cylinders for performing SAW welding. The turning roller consists of four roller assemblies on which a cylindrical setup of job rotates for welding.
The data logger panel/digital processor (40) is a digital processor cum industrial computer. The data logger panel /digital processor (40) include a Wi-Fi Adaptor (42) and Analog to Digital converter unit (44) housed in a dust free protection covered panel (46). The data logger panel/digital processor (40) processes the welding speed related data coming from the holding means' (30) control panel (32). The data logger panel/digital processor (40) hosts processors, converters and memory modules for capturing the data, processing, displaying and sending it to the server database. The data logger panel/digital processor (40) consists of power supply unit, signal converters, industrial grade processor and Wi-Fi terminal for data transfer. In an embodiment, the data from the data logger panel/digital processor is transmitted by using one of the latest technologies such as Wi-Fi, LAN, and Serial communication.
Further, the data logger pane] /digital processor (40) processes signals coming from the temperature sensor unit (60) and temperature control panel (70), welding voltage and current related data from the welding power source (20). The processed data is displayed on a screen of the digital processor (40) and the same is transmitted using Wi-Fi antenna (48a) to a Wi-Fi router (48b). In an embodiment, the screen is a LCD screen. The Wi-Fi Router (48b) in turn records the processed data in a memory device of a central server data bank (80). The central server (80) is used to store the processed data. However, it may be evident

to those skilled in the art that any other memory device such hard disk, compact disk, USB drive and the like can be used for this purpose.
The processed data is stored in the data bank (80) in a tabular form so that the processed data can be fetched and reviewed with ease as shown in figure 5. The processed data can be accessed as and when required from their computers located distantly as shown by component (90). In an embodiment, the audio visual-alarming system for pre-defined parameter ranges is provided by the monitoring system.
The data bank (80) is a memory device located at a central storage area. The data bank (80) has a huge capacity in terms of TB for storage of data. In an embodiment, trending and reviewing software is provided for plotting and displaying the recorded data. Specifically, the monitoring and analyzing of the welding data results in increased productivity.
Referring now to figure 2, there is shown a system for manual arc welding in accordance with an embodiment of the present invention. Specifically, the figure 2 shows the system (200). The system (200) includes a welding means (110), a welding power source (120) and a data logger panel/digital processor (130).
In an embodiment the welding means (110) is a manual arc welding torch. The welding means (110) welds the component (112) for example, the metal component.
The data logger panel/digital processor (130) processes signals coming from a temperature sensor unit (140) and a temperature control panel (150), welding voltage data from the welding power source (120) and welding current data from a current sensor (160). The processed data is displayed on a screen on data logger panel/digital processor (130) and the same is transmitted using Wi-Fi antenna (132) to a Wi-Fi router (134). The Wi-Fi router (134) in turn records the processed

data in the memory device of the central server data bank (170). The processed data is stored in the data bank (170) in specific format so that the data can be fetched and reviewed with ease. This data can also be accessed by plant supervisors as and when required from their computers located in their offices as shown by a component (180),
Referring now to figure 3 in conjunction with figure 1 and 2, there is shown a flowchart for the operation of the system, in accordance with the present invention. The flowchart shows the process (300). The process (300) includes installing the data logger panel/digital processor (40,130) on welding station and providing power supply (20, 120). Further, the process (300) includes initializing the data logger panel/digital processor (40, 130) with identification of a job. Thereafter, the data logger panel/digital processor (40, 130) captures the welding parameters and displays the same on a screen of the data logger panel/digital processor (40, 130). In an embodiment, the welding parameters includes signals coming from the temperature sensor unit (60,140) and the temperature control panel (70,150), welding voltage data from the welding power source (20,120) and welding current data from the current sensor (160). The welding parameters are stored in a memory of the data logger panel/digital processor (40,130). Thereafter, the process includes (300) checking for network connectivity. If the network is ON, the data from the data logger panel/digital processor (40, 130) is transferred and stored in the central server (80, 170). If the network is OFF, the process includes checking of the network connectivity.
Referring now to figure 4 in conjunction with figure 1 and 2, there is shown a flowchart for the operation of the system at user end, in accordance with the present invention. The flowchart shows the process (400). The process includes generating a query by a user for required job data. Thereafter, the query reaches to a central server (80, 170). The process further includes fetching the data according to the required query and Making available the data record on user computer for

analysis. If the user wants to analyze another data, another query is generated and the process id repeated, otherwise the process end.
Advantages of the invention
1. The system (100, 200) is able receive and display the universal inputs coming
from the sensors.
2. All kinds of protocols are supported by adding appropriate protocol converter
modules system (100, 200).
3. The system (100, 200) provides unique technique for capturing the welding
parameters using sensors.
4. The system (100, 200) is capable of handling multiple devices, simultaneous reading as well as monitoring of multiple stations being welded in plant.
5. The system (100, 200) has capability to record the data of more than a year and review system.
6. The transmission and review of the data and multiple accessing facilities is by using one of the latest technologies like Wi-Fi, LAN, and serial communication.
7. The system (100, 200) provides audio visual-alarming system for pre-defined parameter ranges.
8. The system (100, 200) provides a trending and reviewing software for plotting and displaying the recorded data.
9. The system (100, 200) is portable.

10. The system (100, 200) is completely automatic system for data capturing and
storage and transfer without manual intervention.
11. The system (100, 200) is compatible to connect with any power source and
arc welding setup.
12. The. system (100, 200) inter-changeable during failure of device.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

We Claim
1. An automatic system for data capturing, remote monitoring and review of arc welding, the system comprising:
a welding means for welding components, the welding means powered by a power source;
a holding means for holding the components to be welded thereon;
a data logger panel/digital processor for processing welding speed data received from the holding means, signals from a temperature sensor unit and a temperature control panel, welding voltage data from the welding power source and welding current data from a current sensor,
wherein, the processed data is displayed on a screen of the data logger panel/digital processor which is transmitted using Wi-Fi antenna to a Wi-Fi router and the Wi-Fi router in turn records the processed data in a memory device of a central server data bank for analysis and troubleshooting, thereby providing completely automatic system for data capturing, storage and transfer without manual intervention.
2. The system as claimed in claim 1, wherein the processed data is
stored in a data bank for fetching and reviewing with ease for future use.
3. The system as claimed in claim 1, wherein the data from the data
logger panel/digital processor is transmitted by using one of the Wi-Fi, LAN, and
Serial communication.
4. The system as claimed in claim 1, wherein the audio visual-alarming system for pre-defined parameter ranges is provided by the monitoring system.
5. The system as claimed in claim 1, wherein trending and reviewing software is provided for plotting and displaying the recorded data.

6. The system as claimed in claim I, wherein the remote monitoring
and analyzing of the welding data results in increased productivity.