Systems and methods to control welding-type power supplies using AC waveforms and/or DC pulse waveforms

Patent metadata

Field	Value
Publication number	US-12390873-B2
Application number	US-202017066806-A
Country	US
Kind code	B2
Filing date	Oct 9, 2020
Priority date	Nov 1, 2019
Publication date	Aug 19, 2025
Grant date	Aug 19, 2025

Abstract

An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform; an interface configured to receive an input representative of a selected frequency of the AC waveform or the pulse waveform; and control circuitry configured to: determine an amperage parameter of the welding-type power; based on the amperage parameter, determine a range of frequencies of the AC waveform or the pulse waveform; control the interface to output an indication of the selected frequency with respect to the determined range of frequencies; and control the power conversion circuitry to output the welding-type power at the selected frequency and based on the amperage parameter.

First claim

What is claimed is:

1. A welding-type power supply, comprising:
power conversion circuitry configured to convert input power to welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform;
an interface configured to receive an input representative of a selected frequency of the AC waveform or the pulse waveform; and
control circuitry configured to:
determine a value of an amperage parameter of the welding-type power;
based on the value of the amperage parameter, determine a range of frequencies of the AC waveform or the pulse waveform;
control the interface to output a representation of the selected frequency with respect to representations of an upper frequency limit and a lower frequency limit of the determined range of frequencies;
in response to a change in the selected frequency, control the interface to update the representation of the selected frequency with respect to the representations of the upper frequency limit and the lower frequency limit of the range of frequencies; and
control the power conversion circuitry to output the welding-type power at the selected frequency and based on the amperage parameter.

2. The welding-type power supply as defined in claim 1 , wherein each cycle of the AC waveform comprises an electrode negative portion and an electrode positive portion.

3. The welding-type power supply as defined in claim 2 , wherein the amperage parameter comprises at least one of an average current, a root-mean-square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current.

4. The welding-type power supply as defined in claim 1 , wherein the interface is configured to receive the value of the amperage parameter.

5. The welding-type power supply as defined in claim 4 , wherein the control circuitry is configured to limit the selection of the frequency via the operator interface, based on at least one of the upper frequency limit or the lower frequency limit.

6. The welding-type power supply as defined in claim 5 , further comprising an output device configured to output a notification in response to determining that a difference between the selected frequency and a frequency limit is less than a threshold difference.

7. The welding-type power supply as defined in claim 1 , wherein the control circuitry is configured to determine an inductance of a welding-type circuit to which the power conversion circuitry is coupled to output the welding-type power, wherein the control circuitry is configured to determine the frequency based on the value of the amperage parameter and the determined inductance.

8. The welding-type power supply as defined in claim 1 , wherein the control circuitry is configured to determine at least one of a pulse peak current time, a pulse peak current percentage, a pulse background current time, a pulse background current percentage, an AC waveform type, or a weld circuit inductance, wherein the control circuitry is configured to determine the frequency based on the value of the amperage parameter and at least one of the pulse peak current time, the pulse peak current percentage, the pulse background current time, the pulse background current percentage, the AC waveform type, or the weld circuit inductance.

9. The welding-type power supply as defined in claim 1 , wherein each cycle of the pulse waveform comprises a peak current and a background current.

10. The welding-type power supply as defined in claim 1 , wherein the control circuitry is configured to determine the range of frequencies of the AC waveform or the pulse waveform based on a selected one of a plurality of predetermined relationships between the frequency and the value of the amperage parameter.

11. A welding-type power supply, comprising:
power conversion circuitry configured to convert input power to welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform;
an interface configured to receive an input representative of a selected amperage; and
control circuitry configured to:
determine a frequency of the AC waveform or the pulse waveform;
based on the frequency of the AC waveform or the pulse waveform, determine an amperage range;
control the interface to output a representation of the selected amperage with respect to representations of an upper amperage limit and a lower amperage limit of the determined amperage range;
in response to a change in the selected frequency, control the interface to update the representation of the selected amperage with respect to the representations of the upper amperage limit and the lower amperage limit of the determined amperage range; and
control the power conversion circuitry to output the welding-type power at the selected amperage and based on the frequency.

12. The welding-type power supply as defined in claim 11 , wherein each cycle of the AC waveform comprises an electrode negative portion and an electrode positive portion.

13. The welding-type power supply as defined in claim 12 , wherein the selected amperage comprises at least one of an average current, a root-mean-square (RMS) current, a peak current, an electrode negative peak current, an electrode negative commutation current, an electrode positive peak current, or an electrode positive commutation current.

14. The welding-type power supply as defined in claim 11 , wherein the interface is configured to receive a selection of the frequency.

15. The welding-type power supply as defined in claim 14 , wherein the control circuitry is configured to limit the selection of the amperage via the operator interface, based on at least one of the upper amperage limit or the lower amperage limit.

16. The welding-type power supply as defined in claim 15 , further comprising an output device configured to output a notification in response to determining that a difference between the selected amperage and an amperage limit is less than a threshold difference.

17. The welding-type power supply as defined in claim 11 , wherein the control circuitry is configured to determine an inductance of a welding-type circuit to which the power conversion circuitry is coupled to output the welding-type power, wherein the control circuitry is configured to determine the amperage based on the frequency and the determined inductance.

18. The welding-type power supply as defined in claim 11 , wherein the control circuitry is configured to determine at least one of a pulse peak current time, a pulse peak current percentage, a pulse background current time, a pulse background current percentage, an AC waveform type, or a weld circuit inductance, wherein the control circuitry is configured to determine the amperage based on the frequency and at least one of the pulse peak current time, the pulse peak current percentage, the pulse background current time, the pulse background current percentage, the AC waveform type, or the weld circuit inductance.

19. The welding-type power supply as defined in claim 11 , wherein each cycle of the pulse waveform comprises a peak current and a background current.

20. The welding-type power supply as defined in claim 11 , wherein the control circuitry is configured to determine the amperage range of the AC waveform or the pulse waveform based on a selected one of a plurality of predetermined relationships between the frequency and the amperage parameter.

Assignees

• Illinois Tool Works

Inventors

• Pfaller Andrew

Classifications

• B23K9/0953

  using computing means · CPC title

• B23K9/091

  characterised by the circuits · CPC title

• B23K9/1006

  Power supply · CPC title

• B23K9/16 Primary

  making use of shielding gas · CPC title

• B23K9/1043

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