Welding type power supply with output rectifier and phase shift double forward converter

Patent metadata

Field	Value
Publication number	US-11033977-B2
Application number	US-201815955956-A
Country	US
Kind code	B2
Filing date	Apr 18, 2018
Priority date	Apr 21, 2017
Publication date	Jun 15, 2021
Grant date	Jun 15, 2021

Abstract

A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

First claim

The invention claimed is:

1. A welding type power supply comprising:
a phase shifted double forward converter that receives input power and provides a converter output current that includes a dc offset when operating in a phase shifted mode;
a controller, connected to the phase shifted double forward converter to control switching the forward converter;
an output rectifier that receives the converter output current and provides at least a part of a welding type output current, wherein the output rectifier includes at least a first diode and further includes a first diode current path that carries a first diode current, wherein the first diode current path includes a first cathode current path, the at least a first diode and a first anode current path in close physical proximity to the first cathode current path, wherein when the first diode current flows in the first cathode current path it creates a first cathode magnetic field, and wherein when the first diode current flows in the first anode current path it creates a first anode magnetic field, wherein the first cathode current path is disposed and oriented and the first anode current path is disposed and oriented such that the first cathode magnetic field acts to at least partially cancel the first anode magnetic field, wherein the first diode current is at least a first portion of the at least a part of the welding type output current, wherein the at least a first diode is a freewheeling diode, and wherein the output rectifier further includes at least one forward diode and further includes a forward diode current path that carries a forward current, wherein the forward diode current path includes a forward cathode current path, the at least one forward diode and a forward anode current path in close physical proximity to the forward cathode current path, wherein when the forward current flows in the forward cathode current path it creates a forward cathode magnetic field, and wherein when the forward current flows in the forward anode current path it creates a forward anode magnetic field, wherein the forward cathode current path is disposed and oriented and the forward anode current path is disposed and oriented such that the forward cathode magnetic field acts to at least partially cancel the forward anode magnetic field, wherein the forward current is at least a second portion of the at least a part of the welding type output current.

2. The welding type power supply of claim 1 , wherein the first cathode current path is disposed and oriented and the first anode current path is disposed and oriented such that the first cathode magnetic field acts to cancel the first anode magnetic field, and wherein the forward cathode current path is disposed and oriented and the forward anode current path is disposed and oriented such that the forward cathode magnetic field acts to cancel the forward magnetic field.

3. The welding type power supply of claim 2 , wherein the first cathode current path and the forward cathode current path are at least partially shared, and wherein the first anode current path and the forward anode current path are at least partially shared.

4. A method of making a welding type power supply
comprising:
providing a phase shifted dual forward converter;
providing a controller to control the phase shifted dual forward converter;
providing an output rectifier to rectify an output of the phase shifted dual forward converter, including
a first converter forward diode cathode, a first converter freewheeling diode cathode, a second converter forward diode cathode, and a second converter freewheeling diode cathode on a first layer of at least one of a laminated bus and printed circuit board, and further including locating a first converter forward diode anode, a first converter freewheeling diode anode, a second converter forward diode anode, and a second converter freewheeling diode anode on a second layer of the at least one of the laminated bus and printed circuit board; and
locating the first layer near the second layer to at least partially cancel magnetic fields from the anodes with magnetic fields from the cathodes, even when operating in a phase shifted mode by including a dc offset when operating in the phase shifted mode.

5. The method of claim 4 , further comprising locating the first layer near the second layer to cancel magnetic fields from the anodes with magnetic fields from the cathodes.

6. The method of claim 5 , further comprising locating the first layer within 0.01 inches of the second layer.

Assignees

• Illinois Tool Works

Inventors

• Vogel Bernard J
• Anders Adam E
• Sigl Dennis R

Classifications

• B23K9/091

  characterised by the circuits · CPC title

• B23K9/173

  and of a consumable electrode · CPC title

• B23K9/1012

  characterised by parts of the process · CPC title

• B23K9/1056 Primary

  by using digital means (B23K9/1068 takes precedence) · CPC title

• B23K9/1043

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