Hybrid welding control technique

Patent metadata

Field	Value
Publication number	US-9399261-B2
Application number	US-201313802376-A
Country	US
Kind code	B2
Filing date	Mar 13, 2013
Priority date	Mar 13, 2013
Publication date	Jul 26, 2016
Grant date	Jul 26, 2016

Abstract

A hybrid welding system is provided. In one embodiment, the welding system includes an engine-driven generator, an energy storage device, a contactor, and a controller. The controller may be configured to control delivery of weld power from the generator when a commanded output is below a threshold level, and from both the generator and the energy storage when the commanded output is above the threshold level. Closing of the contactor enables the energy storage device to contribute to weld power during welding operations and to be charged by the generator output independent of charging between weld operations. Additional hybrid welding systems and methods are also disclosed.

First claim

The invention claimed is:

1. A welding system comprising:
a generator;
an engine configured to drive the generator to produce a first power output;
an energy storage device configured to discharge energy to produce a second power output;
a controller configured to control delivery of a weld power output from the welding system, the weld power output including power from at least one of the first power output or the second power output, wherein the controller in operation causes the weld output power to include power from the first power output but not the second power output when a commanded output is below a preset threshold and to include power from both the first power output and the second power output when the commanded output is above the preset threshold; and
a contactor controlled by the controller and configured to enable the energy storage device to provide the second power output as part of the weld power output when the commanded output is above the preset threshold, wherein the controller, in operation, receives feedback from the weld power output and commands, automatically and in a closed loop manner, opening or closing of the contactor to provide the second power output as part of the weld output power during weld operations based upon power needed for the welding operation and to enable the first power output to charge the energy storage device independent of a charge state of the energy storage device between weld operations, wherein the controller commands opening or closing of the contactor to enable or disable the energy storage device from providing the second power output based upon the preset threshold of a parameter of welding power.

2. The welding system of claim 1 , comprising weld power converter circuitry configured to modify characteristics of the first power output such that, in operation, the weld power output includes the first power output as modified by the weld power converter circuitry.

3. The welding system of claim 2 , wherein the preset threshold is a current threshold that is at least ninety percent of the maximum current the welding system is configured to output from the weld power converter circuitry.

4. The welding system of claim 3 , wherein the current threshold is 325 amps.

5. The welding system of claim 1 , wherein the energy storage device is a battery.

6. The welding system of claim 1 , wherein the welding system is configured to float charge the energy storage device.

7. A welding system comprising:
a generator;
an engine configured to drive the generator;
an energy storage device;
an output bus configured to receive power from the generator and the energy storage device;
a contactor coupled between the energy storage device and the output bus such that the contactor routes power from the energy storage device to the output bus when the contactor is closed;
a rectifier coupled to the generator; and
a controller configured to receive feedback from output of the welding system and to control voltage of the output bus by commanding, automatically and in a closed loop manner, opening and closing of the contactor;
wherein the welding system, via the controller, is configured to maximize power from the generator and minimize power drawn from the energy storage device during welding operations by opening or closing the contactor to enable or disable the energy storage device from routing power to the output bus based on a preset threshold of a parameter of welding power.

8. The welding system of claim 7 , wherein the controller is configured to control effective power output of the generator to the output bus by controlling the rectifier.

9. The welding system of claim 7 , wherein the controller is configured to control closing of the contactor to allow the energy storage device to output power to the output bus.

10. The welding system of claim 7 , wherein the rectifier is a phase-controlled rectifier.

11. The welding system of claim 7 , comprising a welding torch coupled to the output bus such that the welding torch receives the power from the output bus.

12. A method of operating a welding system including a battery and a generator and configured to provide weld power via an output bus of the welding system, the output bus connected to enable the output bus to receive power from both the battery and the generator, the weld power in operation including power output from one or both of the battery and the generator, the method comprising:
outputting the weld power from the output bus of the welding system; and
receiving, via a controller, feedback based on the output of the welding system and controlling, via the controller, the amount of power drawn from the battery to the output bus by regulating the voltage of the output bus by, automatically and in a closed loop manner, controlling a contactor to enable or prevent the battery from applying a voltage to the output bus based on a preset threshold of a parameter of welding power.

13. The method of claim 12 , comprising:
monitoring a magnitude of a current output command;
closing the contactor to enable the battery to apply voltage to the output bus when the magnitude of the current output command exceeds the preset threshold; and
opening the contactor to prevent the battery from applying voltage to the output bus when the magnitude of the current output command is below the preset threshold.

14. The method of claim 13 , comprising charging the battery when the contactor is open.

15. The method of claim 14 , comprising receiving power from the generator for charging.

16. The method of claim 13 , comprising charging the battery with output power from the generator via the output bus when the contactor is closed.

17. The method of claim 12 , comprising regulating a rotational speed of the generator.

18. The method of claim 17 , comprising controlling a phase-controlled rectifier to control the amount of power provided from the generator to the output bus.

19. The method of claim 17 , comprising detecting that the rotational speed has fallen below a speed threshold and, in response to the rotational speed falling below the speed threshold, closing a contactor to enable the battery to provide power to the output bus.

20. The method of claim 12 , wherein the welding system does not command the amount of power to be drawn from the battery.

Assignees

• Illinois Tool Works

Inventors

• Ulrich James F
• Sykes Allen Raymond

Classifications

• H02J7/865

  Battery or charger load switching, e.g. concurrent charging and load supply (H02J7/50 takes precedence) · CPC title

• B23K9/1012

  characterised by parts of the process · CPC title

• B23K9/095 Primary

  Monitoring or automatic control of welding parameters · 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

• H02J7/0068

  Electricity · mapped topic