Welding system inrush current control system and method

Patent metadata

Field	Value
Publication number	US-10105781-B2
Application number	US-201313835106-A
Country	US
Kind code	B2
Filing date	Mar 15, 2013
Priority date	Jun 8, 2012
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A welding component, such as a remote pendant or wire feeder includes an inrush current control circuit. The welding component may be coupled to a welding power source when the power sources is live and outputting power. Power is stored in the component, such as in capacitors, for operation of a local power supply, such as for an operator interface, display, and the like. Upon connection to the power source, the current application to the capacitors may be delayed to reduce or prevent arcing. The inrush current may also be limited, as may the voltage, to similarly reduce arcing and to provide additional benefits.

First claim

The invention claimed is:

1. A welding component configured to receive power from an activated welding power supply, the welding component comprising:
an energy storage circuit that stores electrical energy when coupled to the activated welding power supply and provides power for operation of the welding component at least during a period of operation of the welding component;
a local power supply within the welding component;
input terminals configured to couple to the activated welding power supply, wherein the activated welding power supply is coupled to the input terminals on a first side of the local power supply and the energy storage circuit is coupled to the local power supply on a second side of the local power supply, opposite the first side, such that each provide power to the local power supply during operation of the welding component;
an accessory coupled to the local power supply and powered by the local power supply during operation;
a switching device coupled to the input terminals and the local power supply on a first side of the switching device, and the energy storage circuit on a second side of the switching device, wherein the switching device is configured to be open during connection of the welding component to the activated welding power supply, and to close after connection to charge the energy storage circuit; and
a current control circuit coupled to the switching device and configured to close the switching device to limit inrush current from the activated welding power supply to the energy storage circuit during initial connection of the input terminals of the welding component to the activated welding power supply.

2. The welding component of claim 1 , comprising electrical components coupled to a gate of the switching device to modulate operation of the switching device and thereby to limit the inrush current.

3. The welding component of claim 1 , wherein the current control circuit is configured to limit arcing of contacts connecting the welding component to the activated welding power supply.

4. The welding component of claim 1 , wherein the current control circuit comprises a capacitor coupled to a gate of the switching device to provide a signal to close the switching device after connection.

5. The welding component of claim 1 , wherein the accessory comprises a user interface and display.

6. The welding component of claim 1 , comprising a voltage control circuit configured to limit voltage of power applied to the energy storage circuit.

7. The welding component of claim 1 , wherein the energy storage circuit is configured to provide power to the local power supply during a ride-through event to maintain power to the accessory of the welding component.

8. The welding component of claim 1 , wherein the current control circuit comprises at least one diode, resistor, or any combination thereof.

9. The welding component of claim 3 , wherein the current control circuit is configured to limit arcing of contacts connecting the welding component to the activated welding power supply to not more than approximately 0.5 Amps.

10. The welding component of claim 4 , comprising a resistor in series between the capacitor and a supply side that receives current from the activated welding power supply upon connection.

11. The welding component of claim 7 , wherein the ridethrough event comprises a loss of open-circuit voltage.

12. A welding component configured to receive power from an activated welding power supply, the welding component comprising:
an energy storage circuit that stores electrical energy when coupled to the activated welding power supply and provides power for operation of the welding component at least during one period of operation of the welding component;
a local power supply within the welding component;
input terminals configured to couple to the activated welding power supply, wherein the activated welding power supply is coupled to the input terminals on a first side of the local power supply and the energy storage circuit is coupled to the local power supply on a second side of the local power supply, opposite the first side, such that each provide power to the local power supply during operation of the welding component;
an accessory coupled to the local power supply and powered by the local power supply during operation;
a switching device coupled to the input terminals and the local power supply on a first side of the switching device, and the energy storage circuit on a second side of the switching device, wherein the switching device is configured to be open during connection of the welding component to the activated welding power supply, and to close after connection to charge the energy storage circuit; and
a current control circuit coupled to the switching device and configured to close the switching device after a delay following initial connection of input terminals of the welding component to the activated welding power supply to limit inrush current from the activated welding power supply to the energy storage circuit.

13. The welding component of claim 12 , wherein the current control circuit is configured to limit arcing while connecting the input terminals of the welding component to the activated welding power supply.

14. The welding component of claim 12 , wherein the current control circuit comprises a capacitor coupled to a gate of the switching device to provide a signal to close the switching device after connection.

15. The welding component of claim 12 , comprising a voltage control circuit configured to limit voltage of power applied to the energy storage circuit.

16. The welding component of claim 14 , comprising a resistor in series between the capacitor and a supply side that receives current from the activated welding power supply upon connection.

17. A welding component configured to receive power from an activated welding power supply, the welding component comprising:
an energy storage circuit that stores electrical energy when coupled to the activated welding power supply and provides power for operation of the welding component at least during one period of operation of the welding component;
a local power supply within the welding component;
input terminals configured to couple to the activated welding power supply, wherein the activated welding power supply is coupled to the input terminals on a first side of the local power supply, and the energy storage circuit is-coupled to the local power supply on a second side of the local power supply, opposite the first side, such that each provide power to the local power supply during operation of the welding component;
an accessory coupled to the local power supply and powered by the local power supply during operation;
a charge-discharge control circuit coupled to the input terminals and the local power supply on a first side of the charge-discharge control circuit, and the energy storage circuit on a second side of the charge-discharge control circuit, the charge-discharge control circuit comprising:
a charge path circuit comprising:
a switching device configured to be open during connection of the welding component to the activated welding power supply, and to close after connection to charge the energy storage circuit; and
a current control circuit coupled to the switching device and configured to close the switching device to limit inrush current into the energy storage circuit following initial connection of input terminals of the welding component to the activated welding power supply; and

a discharge path circuit configured to provid

Assignees

• Illinois Tool Works

Inventors

• Salsich Anthony Van Bergen
• Beistle Edward G

Classifications

• B23K9/1043 Primary

  characterised by the electric circuit (B23K9/1012 takes precedence) · CPC title

• B23K9/1087

  Arc welding using remote control · CPC title

• B23K9/1006 Primary

  Power supply · CPC title

• B23K9/0953 Primary

  using computing means · CPC title