US 12,275,101 B2
Smart spool detection for welding-type systems
Nicholas James Dessart, Neenah, WI (US); and Alan Adam Manthe, New London, WI (US)
Assigned to ILLINOIS TOOL WORKS INC., Glenview, IL (US)
Filed by Illinois Tool Works Inc., Glenview, IL (US)
Filed on Apr. 8, 2020, as Appl. No. 16/842,932.
Prior Publication US 2021/0316384 A1, Oct. 14, 2021
Int. Cl. B23K 9/12 (2006.01); B23K 9/095 (2006.01)
CPC B23K 9/125 (2013.01) [B23K 9/0953 (2013.01); B23K 9/0956 (2013.01)] 8 Claims
OG exemplary drawing
 
1. A welding system, comprising:
a wire feeder comprising:
a spindle configured to retain a wire spool comprising a first outer flange and a second outer flange, wherein a wire is retained on the wire spool between the first outer flange and the second outer flange,
a first sensor configured to detect a presence or proximity of the first outer flange of the wire spool, and
a second sensor configured to detect a radius of the wire retained on the wire spool or a distance from the second sensor to the wire retained on the wire spool; and
control circuitry configured to:
determine a spool size of the wire spool based on whether the presence or proximity of the first outer flange of the wire spool is detected by the first sensor,
determine a remaining amount of wire on the wire spool based on the spool size and the radius of the wire retained on the wire spool or the distance from the second sensor to the wire retained on the wire spool detected by the second sensor, and
generate an output based on the remaining amount of wire.