System and method of communicating in a welding system over welding power cables

Abstract

Systems and methods of the present invention are directed to welding systems having a welding power supply and wire feeder, where the power supply and wire feeder communicate over the welding power cables. In exemplary embodiments, the wire feeder communicates with the power supply over the welding cables using current draw pulses which are generated and recognized by the power supply. Similarly, the power supply generates voltage pulses which are transmitted over the welding power cables and recognized by the wire feeder.

We claim: 
     
         1 . A welding system, comprising:
 a welding power source comprising a controller having a first receiver and a first transmitter;   a wire feeder comprising a communication circuit having a second receiver, a second transmitter, and a current sink circuit having a current shunt regulator and switches; and   at least one welding power cable coupled to each of the welding power source and the wire feeder and configured to carry a welding power from the welding power source to the wire feeder during a welding operation;   wherein the wire feeder is configured to communicate with the welding power source over the at least one welding power cable by generating a current draw signal, via at least the current sink circuit of the wire feeder, which is detected by at least the first receiver of the welding power source via current sensing;   wherein the welding power source is configured to communicate with the wire feeder over the at least one welding power cable by generating a voltage pulse signal, via at least the first transmitter of the welding power source, which is detected by at least the second receiver of the wire feeder via voltage sensing;   wherein the current draw signal comprises a plurality of current draw pulses generated at the wire feeder and the voltage pulse signal comprises a plurality of voltage pulses generated at the welding power source.