Cutting Torch Height Control Apparatus

This invention relates to an apparatus for controlling the height of a cutting torch above a workpiece which is operable in a manual mode, a semi-automatic mode, and a fully automatic mode.

In a flame cutting machine one or more gas operated cutting torches are acted on by a drive mechanism which causes the torches to cut along one or more workpieces in accordance with a predetermined pattern. Efficient use of such machines is dependent on maintaining a precise optimum flame height or spacing of the torch from the associated workpiece as heat concentration varies substantially along the length of the flame. If the torch to workpiece spacing varies significantly in the course of cutting a workpiece, a nonuniform or possibly incomplete cut may be made and heat utilization becomes less efficient. The need for adjustment of torch height in the course of a cutting operation may arise from the fact that the workpiece has a non-planar configuration. Moreover, sensitivity is such that slight unintentional irregularities in the surface of nominally flat plate stock may significantly affect cutting efficiency and accuracy.

In some prior flame cutting machines, adjustment of the flame height during the course of a cutting operation, must be done manually by an operator who continually observes the cutting operation. A fully manual flame height control system has several disadvantages. First, more or less continual attention is required and the operator is thereby prevented from accomplishing other tasks during the sometimes lengthy cutting operations. Second, the operator's task becomes more difficult, and quality of results is adversely affected in proportion to the number of torches employed on the cutting machine. Finally, the quality of the flame height control varies widely among different operators and is less than optimum under the best of circumstances. For these reasons, flame cutting machines are frequently provided with means for automatically controlling torch height during cutting operations.

Such automatic control requires a servomotor for advancing or retracting the torch relative to the workpiece in response to control signals and further requires apparatus for sensing the spacing of the torch from the workpiece surface in order to transmit corrective control signals to the servomotor when necessary.

Torch to workpiece spacing sensing devices employed in prior automatic torch height controls have included a variety of wheels, rollers, runners, sliding contacts and electrical capacitance measuring plates which extend from the torch towards the workpiece. These systems are complex, prone to malfunction and experience maintenance problems and are inherently susceptible to error in the presence of varying conditions, such as slag popping, at the surface of the workpiece. Moreover, such devices do not sense the spacing of the workpiece from the torch at the precise point of contact of the flame therewith but instead sense the spacing at a location displaced to one side of the flame.

Ideally, the sensing devices employed in an automatic torch height control should not require any mechanism extending from the torch to the surface of the workpiece and should act to sense changes in the spacing of the torch and workpiece at the precise point of contact of the flame with the workpiece. Further, such sensing devices should individually control each torch in a multiple bank thereof while providing manual adjustment of the spacing of all torches and manual initiated raising or lowering of all torches simultaneously or individually.

A system for maintaining a predetermined selectable torch to workpiece spacing in a flame cutting machine which does not require sensor structure extending from the torch to the workpiece is described in U.S. Pat. No. 3,823,928 which issued on July 16, 1974 to B. L. Stolin and R. D. Brown. The system is sensitive to minute changes in spacing of the torch from the precise point of contact of the flame with the workpiece. For this purpose, an electrical voltage is applied between the torch and the workpiece and an electrical current travels through the cutting flame. The flame is effectively a variable electrical resistor, the resistance of which is a function of the spacing of the workpiece from the torch. During operation, any variation of the electrical resistance of the flame is detected and a correction signal is generated to actuate a servomotor which restores the torch to workpiece spacing to the desired value. In one form of the system, a plurality of torches are utilized and the height control system provides for manual selection of a basic reference voltage that determines the automatically maintained spacing at all torches from the associated workpieces while further providing for individual fine adjustment of torch to workpiece spacing at each torch. Also in the preferred form, the control system provides a safety shutdown for preventing the automatic height control system from driving a torch towards the workpiece when the flame lengthens abruptly as a result of passing off the edge of the workpiece.

As mentioned the flame is a variable resistor so that the flame generated voltage varies, sporadically at times, with the flame. This voltage is spontaneously generated by the action of the flame on the workpiece. Electronic systems are adversely affected by such sporadic signals generated by the flame. The problem is further compounded where the electrical circuits are analog circuits which are subject to drifting. Where drifting is severe, the system must be calibrated before each use to obtain the desired results. The calibration procedure is time consuming which decreases productivity and increases costs.

The flame will generally vary or flutter because it responds to changes in gas pressures, ambient air currents, and irregularities in the surface of the workpiece. It has been found that an analog system must be calibrated before each use which means the analog system will not be a fully automatic system. It is desirable to have a torch height control which can operate in a manual mode, a semi-automatic mode or a fully automatic mode to allow the operator to exercise that degree of personal attention required for the particular cutting job thereby freeing the operator to perform other tasks as desired during the cutting operation.

In one aspect of the present invention, an apparatus for controlling the distance of a device from a reference point comprises means for moving the device toward and from the reference point and means for generating a position signal representative of the distance of the device from the reference point and storing the distance information contained in the position signal. A computing means compares the actual position of the device as indicated by the distance information in the storing means with a reference device position and controllably delivers a signal to the moving means. The apparatus is operable in an automatic mode in which the computing means is free to deliver the signal to the moving means and exercise control over the position of the device.

In another aspect of the present invention, an apparatus for controlling the distance of at least one cutting torch from an associated reference point includes means for moving the torch toward and from the reference point and means for generating a position signal representative of the distance the torch is spaced from the reference point. A generating means produces a reference signal representative of a desired distance between the torch and reference point. Means are also provided for comparing the position and reference signals and energizing the moving means to move the torch until the actual torch position substantially equals the desired torch position.

In a further aspect of the present invention an apparatus for controlling the height of at least one cutting torch above an associated workpiece comprises motor means for moving the torch toward and from the workpiece, drive means for directing the motor means to move the torch toward and from the workpiece, and means for generating a digital resistance signal representative of the resistance of the cutting torch flame. Means are provided for operating the apparatus in a manual, semi-automatic or automatic mode. Means are provided for receiving the resistance signal representative of the flame resistance, comparing the torch position with a preselected torch position in the automatic mode, and energizing the drive means and moving the torch until the torch position is substantially equal to the preselected torch position.

The apparatus controls the height of one or more cutting torches above a workpiece by sensing the height of the torch and comparing the actual height with a reference height and moving the torch toward or from the workpiece until the actual height substantially equals the desired height. The apparatus is operable in a manual mode, a semi-automatic mode or a fully automatic mode to allow an operator to exercise any desired degree of control.

FIG. 1 is a block diagram of an apparatus for controlling the height of a cutting torch above a workpiece;

FIG. 2 is a front view of operator controls and indicators;

FIG. 3 is a connection diagram;

FIG. 4 is a schematic diagram of a portion of the operation controls and is connected to FIG. 5 along line A--A;

FIG. 5 is a schematic diagram of a portion of the operator controls and is connected to FIG. 4 along line A--A;

FIG. 6 is a portion of a flowchart illustrating the sequential operation of the apparatus of FIG. 1 and is connected to FIG. 7 along line B--B;

FIG. 7 is the remainder of the flow chart of FIG. 6 and is connected to FIG. 6 along line B--B; and

FIG. 8 is a block diagram of an apparatus for controlling the height of a cutting torch above a workpiece similar to FIG. 1 but illustrating another embodiment.

Referring to FIG. 1, a cutting torch height control system 10 controls the distance of a cutting torch 12 from a workpiece 14. The torch control system 10 includes a signal processor 16 which measures characteristics, such as voltage and current, of the torch flame and generates a signal representative of the resistance of the torch flame. Since flame resistance varies with the distance of the torch 12 from the workpiece 14, the resistance signal from the signal processor 16 is representative of the distance of the torch 12 from the workpiece 14. The resistance information from the signal processor 16 is stored in the memory of a microcomputer 18. The flame also generates a voltage which is sensed and stored in the memory of the computer 18. The flame generated voltage is referred to as the floating voltage because the voltage is present even when there is no current passing through the flame and because the voltage level varies from one operation to the next operation and during each operation due to workpiece temperature and other continually changing variables.

Basically, the signal processor 16 samples the torch flame at a preselected rate at preselected intervals and generates resistance information which is received by the computer 18. The computer 18 averages the information for each sample and compares the averaged data with reference height data generated by controls 20 set by an operator. After the comparison, the computer 18 activates a drive control 26 which activates a torch lifter 24 to move the torch 12 toward or from the workpiece 14 depending on whether the average data indicates that the torch-to-workpiece spacing is less or greater than the spacing indicated by the reference height data. A group of operator indicators 22 indicates the mode of operation, manual, semi-automatic or automatic, of the control system and other conditions as will be hereinafter more fully explained.

Referring to FIGS. 1 and 3, in a preferred embodiment for operating four cutting torches, the microcomputer 18 is an Intel SBC 80/05 with an SBC116 memory and an SBC556 input/output. The computer 18 contains three input ports, X+0, X+2 and X+4, containing pin terminals J1, 33-48, 1-16 and J2, 33-48 and two output ports, X+1 and X+5, containing pin terminals J1, 17-32 and J2, 17-32. Output port X+1 is connected to the motor drives 26 and an up or down signal is delivered to the motor drives for moving the torches up or down, one at a time or all at once. Output port X+5 is connected to the operator indicator panel 22 to activate various operator indicators. The input ports X+0, X+2 and X+4 receive signals from the operator control panel 20.

Each torch lifter 24 is an electric motor or the like and is connected to a respective torch 12 and controlled by a motor drive 26 or by an operator control depending on the particular mode of operation of the control system 10.

Referring to FIG. 2, the operator controls 20 and indicators 22 are conveniently mounted on a single panel. The panel contains four lock-out switches 28,30,32,34, four jog switches 36,38,40,42, a master jog-up switch 44, and an all up switch 50. The panel also contains a control switch 52 and indicator 54, a semi-automatic/automatic switch 56 and indicators 58,60, a reset switch 62, and a thumbwheel switch 64. There is a thumbwheel/torch switch 66, a lost cut switch 68 and visual and audible lost cut indicators 70,72. The associated control circuitry is shown in FIGS. 4 and 5. The four lock-out switches 28,30,32,34 can each disable a respective torch 12 so that the torch remains at its upmost position and not be affected by other operator controls 20. The jog switches 36,38,40,42 are for facilitating movement of the torches, one torch at a time while the master jog switches 44,46 can cause all four torches to move simultaneously. The preposition switch 48 causes the torches to move to a preselected position relative to the workpiece 14. The all up switch 50 is for sending the torches to their upmost position. The control switch 52 and semi-automatic/automatic switch 56 are for determining whether the system operates in the manual, semi-automatic or fully automatic mode as indicated by the control, semi-automatic and automatic indicating lamps 54,58,60. The thumbwheel switch 64 is for setting the reference torch height when the thumbwheel/torch switch 66 is in the thumbwheel position while the jog switches are for setting the reference height when switch 66 is in the torch position. The lost cut switch 68 is for enabling the lost cut indicating lamp 70 and audible alarm 72.

Referring to FIGS. 1-5, with the control switch 52 in the off position, the cutting torches 12 are operated in a manual mode. In the manual mode, the operator moves all the torches 12 up in response to positioning the master jog-up switch 44 of down in response to positioning the master jog-down switch 46. The torches 12 can be individually moved up or down in response to positioning the individual jog switches 36,38,40 and 42.

The motor drive 26 contains eight solid state relays for controlling up and down operation of the torches 12. Relays 74,76,78, and 80 control the upward movement of an associated torch while relays 82,84,86 and 88 control the downward movement of the associated torch. Relays 74,76,78 and 80 are respectively connected to terminals J1-31, J1-27, J1-23 and J1-19 and relays 82,84,86 and 88 are connected to terminals J1-29, J1-25, J1-21, and J1-17 in series with lockout switches 28,30,32 and 34, respectively.

The master jog-up switch 44 is connected to relays 74,76,78 and 80 and cause all the torches to move upward when switch 44 is activated. The master jog-down switch 46 is connected to relays 82,84,86 and 88 and cause all the torches to move downward when switch 46 is activated. A normally closed contact of the master jog-down switch 46 is connected to line 90 and connected in series with a normally closed contact of the master jog-up switch 44 which in turn is connected to the four jog switches 36,38,40 and 42. When all the jog switches are in their normal positions line 90 is connected to terminals J1-42, J1-44, J1-46, and J1-48. These inputs notify the computer that a torch has or has not been manually repositioned.

The control switch 52 has one terminal connected to 24 VDC supply. In the "on" position, the control switch 52 connects the supply voltage to the control lamp 54 and to terminals J1-18,20,24,26,28,30 and 32. The control switch 52 also connects the audible alarm 72 to terminal J2-23. The alarm and indicators 54,58,60 and 70 are all connected to the common 24 V return. When the control switch 52 is in the "off" position, the apparatus 10 operates in the manual mode. The operator can use the jog switches in the manual mode. When the control switch is in the "on" position, the apparatus 10 operates in either the semi-automatic mode or fully automatic mode.

In the semi-automatic mode, the semi-automatic/automatic switch 56 is in the semi-automatic position which connects the 24 VDC supply to line 90. The operator can use the jog switches in the semi-automatic mode as well as the preposition switch 48 and all up switch 50. The preposition switch 48 connects line 90 to terminal J1-6 and the all up switch 50 connects line 90 to terminal J1-8. Operation of the preposition switch 48 frees the thumbwheel 64 for setting a reference position at which the torches will automatically be positioned in response to activating the preposition switch 48. Operation of the all up switch 50 drives the torches to their full up position. The computer 18 does not exercise automatic control over the torch height in the semi-automatic mode, except with regard to the preposition function.

When the switch 56 is in the semi-automatic position, the indicating lamp 58, which is connected to terminal J2-29, is illuminated and when the switch 56 is in the automatic position, the indicating lamp 60, which is connected to terminal J2-31, is illuminated.

In the automatic mode, the switch 56 is in the automatic position, as indicated in FIG. 4, which connected the 24 VDC supply to terminal J1-16. The terminals J1-1,3,5,7,9,11,13,15,33,35,37,39,41,43,45 and 47 and terminals J2-33,35,37,39,41,43,45 and 47 are connected to the 24 VDC common return. Terminals J2-18,20,22,24,26,28,30 and 32 are connected to the 24 VDC supply. The operator jog switches are not operative in the automatic mode; the computer 18 is in full control.

There are two modes of automatic operation. In one mode the thumbwheel/torch reference switch 66 is in the thumbwheel position which connects the 24 VDC supply to terminal J1-14 and enables the thumbwheel 64. Reference heights in the form of digital signals are taken from the thumbwheel 64 and can be changed by the operator as desired. The preposition and all up switches 48,50 are functional in this mode as well as the lost cut switch 68 which connects terminal J1-10 and the line 90. The lost cut indicating lamp 70 is connected to terminal J2-25. This mode of operation is preferable and controls can be left in this position for most cutting operations.

In the second automatic mode, switch 66 is set to the torch reference position which connects the 24 VDC supply to the line 90 and enables the operator jog switches. Height references are taken from actual torch positions as set by the jog switches rather than from the thumbwheel 64. This mode allows individual height references to be maintained for each torch. Other switches function as in the first automatic mode with the reset switch 62 being connected to the computer 18 for resetting the computer 18 when activated.

Referring to FIG. 8, an alternate embodiment of the apparatus 10' is shown in which the microcomputer 18' is different than in FIG. 1. The difference is that the microcomputer 18' shares a memory 92 with the signal processor 16'. By this construction, the input/output to the memory 92 can be another microcomputer thereby facilitating the use of the apparatus 10' with other positional apparatus.

Referring to the flowchart of FIGS. 6 and 7, when the apparatus 10 is turned on, the microcomputer 18 initializes its central processing unit, registers, and input/output ports. A watchdog timer 94 is set for about 150 milliseconds. If the watchdog timer 94 ever times out or if the reset switch 62 is activated, an interrupt signal is generated which functions to restart the program.

If the switch 56 is in the semi-automatic position, the lamp 58 comes on while the lamp 60 is off. The lost cut lamp 70 and audible alarm 72 are off in this mode. If the torches are to be prepositioned by use of the preposition switch 48, the values are read from the thumbwheel 64 and the program progresses to block 96 of the flowchart. If the torches are not prepositioned, the program advances to block 96. At block 96, the torches are all driven to their upmost position if switch 50 has been activated, and the program progresses to block 98. The program advances from 96 to 98 if the switch 50 has not been activated, but the torches maintain their previous positions. At block 98 there is a delay to allow updated torch position data to be obtained, after which the cycle repeats itself by again setting the watchdog timer 94 and operating in the semiautomatic position by the operator.

If switch 56 is in the automatic position, the lamp 60 is "on" and lamp 58 is "off". The program advances as before to detect whether the preposition and all up switches 48,50 have been activated. If preposition switch 48 is activated, a preposition value is read from the thumbwheel 64. After prepositioning, activation of the all up switch 50 will drive all torches to their upmost position. Next, the program scans the thumbwheel/torch switch 66.

If switch 66 is in the thumbwheel position, the torch reference values are taken from the thumbwheel 64 and the actual torch values are obtained from the signal processor 16 at block 100. If the lost cut switch 68 is "on", the lamp and alarm 70,72 are activated when there is a loss of cut. Naturally, there is no visual or audible alarm when the lost cut switch 68 is "off".

Next, an output word is formatted for the torches which are not at the reference position and these out of position torches are driven toward the reference position. The program then repeats itself by setting the watchdog timer 94 and proceeding.

In the automatic mode with the thumbwheel/torch switch 66 in the torch position, the program advances to block 102. If this is the first pass, torch values are obtained from the signal processor 16 and used to create the reference position and the program advances to block 104 to determine if any torches have been jogged to change their position. If this is not the first pass, the program advances to block 104. If there are no jogs, the program proceeds to block 100.

If there is a jog, actual torch values are obtained from the signal processor 16. The reference values of the jogged torches are replaced by the actual torch values and the program advances to block 104 to determine if there are any more jogs.

Referring to FIGS. 1 and 8, the apparatus 10 operates with the information related to torch flame resistance provided to it by the signal processor 16. This information is digitized, consisting of two 8-bit binary words for each torch 12, and passed through a common memory area (92 FIG. 8). This information is in the form of an array that is updated every 50 to 80 milliseconds.

The information consists of one binary word representing torch floating voltage and one word representing torch flame resistance for each torch. The array is preferably accessed periodically about every 30 milliseconds. Bus control is implemented such that data will not be altered while a transfer is in progress. The apparatus 10 forms a local array consisting of resistance and floating voltage information for each torch, plus a reference level for each torch. The reference may come from a thumbwheel position dialed by the operator or from a preset torch position adjusted by the operator.

In the fully manual mode, the operator can jog the torches 12 with the hardwired jog switches 36,38,40,42,44 and 46. The computer 18 tracks the torches 12 but exercises no control.

In the semi-automatic mode, the operator can jog the torches 12 as desired. He can take advantage of the preposition and all up features which allow the torches 12 to automatically drive until they detect the workpiece 14 and stop at a preselected height, or to drive to the upmost position and stop at the torch of the respective preposition or all up switch 48 or 50. In the preposition mode, if positioning cannot be accomplished within an established time frame, preposition will be aborted and the torches will return to the full up position. The computer 18 will still not exercise automatic control over torch height in the semi-automatic mode.

In the fully automatic mode using the thumbwheel 64, the computer 18 is in full control of the torch position. The operator jog switches 36,38,40,42,44 and 46 are not operative. Height references are taken from the thumbwheel switch 64 and can be changed as desired. All operator options such as preposition, all up, and lost cut are functional. The apparatus 10 can be left in this mode under most circumstances of torch operation. This is desirable because it requires a minimum of operator intervention.

In the fully automatic mode using torch reference position of the thumbwheel/torch switch 66, the apparatus basically functions as described immediately above except that the height references are derived from actual torch positions established by the operator rather than from the thumbwheel 64. These torch references are established by using the operator jog switches 36,38,40,42,44 and 46 which are activated when switch 66 is in the torch reference position. This mode of operation allows individual height references to be maintained for each torch.

In the full automatic mode, freeing of operator time is a prime consideration. The preposition capability is available using the preposition switch 48. The lost cut feature, using the lost cut switch 68, is available which allows the apparatus 10 to sound the alarm 72 or exercise direct control when it is sensed that one or more torches that were cutting have lost the cut. This sensing is accomplished by monitoring the torch floating voltage, which has been found to experience an abrupt negative-going transition upon loss of cut. These torches will continue to track the workpiece 14, even though they are not cutting, so long as the frame is present. The lost cut condition is defined as a preselected combination of flame resistance and floating voltage. The ability to detect a loss of cut is important for fully automatic machines such as NC/CNC units.

In the case of an extinguished torch, or any torch left unlit, the apparatus recognizes the no flame condition and drives the affected torches to the upward most position. The edge of the workpiece 14 is also detected and the affected torches are driven to the upward most position in preparation for the next cut. When the edge is encountered the flame current approaches zero.

Control of the torch lifters 24 is of a proportional nature. A large error in position, determined by a large differential between the actual torch resistance and the reference value, causes rapid torch motion to reduce the error. A small error in position causes the torch to travel in small increments with a pause between steps to allow updating the actual torch resistance. Where the error exceeds a preselected value, the torch travels rapidly until the error is reduced below the preselected value. This prevents the torch from overshooting the desired position. Also, the torch preferably travels at the same rate of speed in both the up and down positions which is accomplished by increasing speed in the up direction to compensate for the effects of gravity on the torch. Since updating occurs in excess of twelve times per second, excellent control of torch position results from this method.

For normal cutting operations, it is desirable to place the apparatus 10 in the automatic mode at the beginning of a run and leave it in the automatic mode until a new set up is required. Due to the default up design, the torches will always be in the upmost position, out of the operators way, except when actually tracking the workpiece 14.

While the apparatus 10 has been described as it particularly relates to a cutting torch 12, the apparatus 10 works equally well with other devices operated with servo-motors or other means and for which position signals can be obtained. For example, the apparatus 10 could be used to control a drill or other machine tool. The depth of the drill bit into a workpiece could be controlled by generating a signal representative of actual depth and dialing the desired depth on the thumbwheel 64. Likewise, the speed of the drill could be controlled.

One implementation of the flowchart of FIGS. 6 and 7 yields the following program for the Intel SBC 80/05 in hexadecimal form: ##SPC1##

The same flowchart could obviously be implemented with any number of programs.

Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims.