Welding system and method of welding

Patent metadata

Field	Value
Publication number	US-11673202-B2
Application number	US-202016928132-A
Country	US
Kind code	B2
Filing date	Jul 14, 2020
Priority date	Feb 7, 2005
Publication date	Jun 13, 2023
Grant date	Jun 13, 2023

Abstract

A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and converts the first DC output signal to a second DC output signal of the second stage; and a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module within a first housing structure and the third stage is assembled into a second module having a separate housing structure connectable to the first module with long power cables. The second module also includes wire feeding systems and electronics.

First claim

What is claimed is:

1. A power supply system for an electric arc welding process, said power supply system comprising:
a first power supply module including:
an input stage having an AC input and a first fixed DC output signal, wherein said input stage includes a rectifier and a power factor correcting converter;
a second stage in the form of an unregulated DC to DC converter, unregulated by a feedback signal from the electric arc welding process, having an input connected to said first fixed DC output signal, a network of switches switched at a high frequency with a given duty cycle to convert said input into a first internal AC signal, an isolation transformer with a primary winding driven by said first internal AC signal and a secondary winding for creating a second internal AC signal, and a smoothing choke and a rectifier to convert said second internal AC signal into a second fixed DC output signal of said second stage with a magnitude related to said duty cycle of said switches; and

a second power supply module on a dedicated support structure separate from the first power supply module, wherein the second power supply module comprises:
a third stage comprising switching circuitry configured to convert said second fixed DC output signal to a welding output for welding in said process, wherein the second power supply module is operatively connected to receive at least one of a voltage feedback signal of the welding output and a current feedback signal of the welding output, and regulate the welding output based on the at least one of a voltage feedback signal of the welding output and a current feedback signal of the welding output, wherein the second power supply module is located in a wire feeder housing remote from the first power supply module.

2. The power supply system of claim 1 , wherein said third stage includes a chopper with a power switch operated at a given frequency.

3. The power supply system of claim 2 , wherein said chopper is a dual mode chopper with a first polarity path with a first power switch and a first polarity switch and a second polarity path with a second power switch and a second polarity switch, wherein the first polarity path and the second polarity path are opposite polarity paths between an electrode and a workpiece, and the dual mode chopper is selectively operable in any one of an AC mode, a DC positive mode, and a DC negative mode.

4. The power supply system of claim 3 , including a controller within said second power supply module with a first mode alternately operating said chopper between first and second polarity paths and a second mode operating said chopper in only one of said polarity paths.

5. The power supply system of claim 1 , wherein said third stage includes a circuit with a power switch to perform an STT welding process.

6. A power supply system for an electric arc welding process, said power supply system comprising:
a first power supply module including:
an input stage having an AC input and a first fixed DC output signal, wherein said input stage includes a rectifier and a power factor correcting converter;
a second stage in the form of an unregulated DC to DC converter, unregulated by a feedback signal from the electric arc welding process, having an input connected to said first fixed DC output signal, a network of switches switched at a high frequency with a given duty cycle to convert said input into a first internal AC signal, an isolation transformer with a primary winding driven by said first internal AC signal and a secondary winding for creating a second internal AC signal, and a smoothing choke and a rectifier to convert said second internal AC signal into a second fixed DC output signal of said second stage with a magnitude related to said duty cycle of said switches; and

a second power supply module on a dedicated support structure separate from the first power supply module, wherein the second power supply module comprises:
a third stage comprising switching circuitry including a chopper with a power switch operated at a given frequency and configured to convert said second fixed DC output signal to a welding output for welding in said process, wherein the second power supply module is operatively connected to receive at least one of a voltage feedback signal of the welding output and a current feedback signal of the welding output, and regulate the welding output based on the at least one of a voltage feedback signal of the welding output and a current feedback signal of the welding output.

7. The power supply system of claim 6 , wherein said chopper is a dual mode chopper with a first polarity path with a first power switch and a first polarity switch and a second polarity path with a second power switch and a second polarity switch, wherein the first polarity path and the second polarity path are opposite polarity paths between an electrode and a workpiece, and the dual mode chopper is selectively operable in any one of an AC mode, a DC positive mode, and a DC negative mode.

8. The power supply system of claim 7 , including a controller within said second power supply module with a first mode alternately operating said chopper between first and second polarity paths and a second mode operating said chopper in only one of said polarity paths.

9. The power supply system of claim 6 , wherein said third stage includes a circuit, with a power switch to perform an STT welding process.

10. A power supply system for an electric arc welding process, said power supply system comprising:
a first power supply module including:
an input stage having an AC input and a first fixed DC output signal;
a second stage in the form of an unregulated DC to DC converter, unregulated by a feedback signal from the electric arc welding process, having an input connected to said first fixed DC output signal, a network of switches switched at a high frequency with a given duty cycle to convert said input into a first internal AC signal, an isolation transformer with a primary winding driven by said first internal AC signal and a secondary winding for creating a second internal AC signal, and a smoothing choke and a rectifier to convert said second internal AC signal into a second fixed DC output signal of said second stage with a magnitude related to said duty cycle of said switches; and

a second power supply module on a dedicated support structure separate from the first power supply module, wherein the second power supply module comprises:
a third stage comprising switching circuitry including a chopper with a power switch operated at a given frequency and configured to convert said second fixed DC output signal to a welding output for welding in said process, wherein the second power supply module is operatively connected to receive at least one of a voltage feedback signal of the welding output and a current feedback signal of the welding output, and regulate the welding output based on the at least one of a voltage feedback signal of the welding output and a current feedback signal of the welding output, wherein the second power supply module is located in a wire feeder housing remote from the first power supply module.

11. The power supply system of claim 10 , wherein said chopper is a dual mode chopper with a first polarity path with a first power switch and a first polarity switch and a second polarity path with a second power switch and a second polarity switch, wherein the first polarity path and the second polarity path are opposite polarity paths between an electrode and a workpiece, and the dual mode chopper is selectively operable in any one of an AC mode, a DC positive mode, and a DC negative mode.

12. The power s

Assignees

• Lincoln Global Inc

Inventors

• Kooken Todd E
• Luo Lifeng
• Krueger Matthew J

Classifications

• B23K9/09

  Arrangements or circuits for arc welding with pulsed current or voltage · CPC title

• B23K9/1075 Primary

  Parallel power supply, i.e. multiple power supplies or multiple inverters supplying a single arc or welding current · CPC title

• B23K9/091

  characterised by the circuits · CPC title

• B23K9/173

  and of a consumable electrode · CPC title

• B23K9/1043

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