Power converter for engine generator

Patent metadata

Field	Value
Publication number	US-9407185-B2
Application number	US-201414583417-A
Country	US
Kind code	B2
Filing date	Dec 26, 2014
Priority date	Jul 27, 2012
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

Abstract

A power converter for an engine generator includes an insulative support that receives and supports circuit components for converting incoming AC power to desired power, such as power suitable for a welding application. One or more rectifier modules are provided that are received and supported by the support. Three such modules may be provided for receiving three phase power from a generator. DC power from the rectifier module is applied to DC bus plates. The plates may be coupled to capacitors. A power conversion circuit, such as a buck converter, is coupled to the DC bus plates to convert the DC power to output power.

First claim

The invention claimed is:

1. A power converter comprising:
an insulative support;
a rectifier module supported by the insulative support, the rectifier module configured to receive AC power from a source;
a plurality of plate-like DC bus elements disposed in the insulative support and electrically insulated from each other, the plurality of plate-like DC bus elements receiving DC power from the rectifier module;
a power converter circuit contacting the plurality of plate-like DC bus elements to receive the DC power and to convert the DC power to a desired output power; and
a control circuit coupled to the power converter circuit and configured to command operation of the power converter circuit during operation.

2. The power converter of claim 1 , comprising three rectifier modules supported by the insulative support for receiving and converting three phase AC power from the source to DC power for application to the plurality of plate-like DC bus elements.

3. The power converter of claim 1 , comprising one or more capacitors supported by the insulative support and electrically coupled to the plurality of plate-like DC bus elements.

4. The power converter of claim 3 , wherein the insulative support comprises one or more receptacles for receiving a respective capacitor, each receptacle fitting tightly around the respective capacitor for stabilizing the respective capacitor.

5. The power converter of claim 1 , wherein the power converter circuit comprises a buck converter.

6. The power converter of claim 1 , wherein the insulative support comprises upper and lower housings enclosing and electrically insulating the rectifier module, the plurality of plate-like DC bus elements, and the control circuit from each other.

7. The power converter of claim 1 , wherein the insulative support receives and supports the rectifier module in a tongue-in-groove arrangement.

8. A power supply comprising:
an engine;
a generator coupled to the engine and configured to generate AC power in operation; and
a power converter comprising an insulative support, a rectifier module supported by the insulative support, the rectifier module configured to receive AC power from the generator, a plurality of plate-like DC bus elements disposed in the insulative support and electrically insulated from each other, the plurality of plate-like DC bus elements receiving DC power from the rectifier module, a power converter circuit contacting the plurality of plate-like DC bus elements to receive the DC power and to convert the DC power to a desired output power, and a control circuit coupled to the power converter circuit and configured to command operation of the power converter circuit during operation.

9. The power supply of claim 8 , comprising three rectifier modules supported by the insulative support for receiving and converting three phase AC power from the generator to DC power for application to the plurality of plate-like DC bus elements.

10. The power supply of claim 8 , comprising one or more capacitors supported by the insulative support and electrically coupled to the plurality of plate-like DC bus elements.

11. The power supply of claim 10 , wherein the insulative support comprises one or more receptacles for receiving a respective capacitor, each receptacle fitting tightly around the respective capacitor for stabilizing the respective capacitor.

12. The power supply of claim 8 , wherein the power converter circuit comprises a buck converter.

13. The power supply of claim 8 , wherein the insulative support comprises upper and lower housings enclosing and electrically insulating the rectifier module, the plurality of plate-like DC bus elements, and the control circuit from each other.

14. The power supply of claim 8 , wherein the insulative support receives and supports the rectifier module in a tongue-in-groove arrangement.

15. The power supply of claim 8 , wherein the desired output power is suitable for a welding application.

16. A power supply comprising:
an engine;
a generator coupled to the engine and configured to generate three phase AC power in operation; and
a power converter comprising an insulative support, three rectifier modules supported by the insulative support and configured to receive the three phase AC power from the generator, a plurality of plate-like DC bus elements disposed in the insulative support and electrically insulated from each other, the plurality of plate-like DC bus elements receiving DC power from the three rectifier modules, a power converter circuit contacting the plurality of plate-like DC bus elements to receive the DC power and to convert the DC power to output power suitable for a welding application, and a control circuit coupled to the power converter circuit and configured to command operation of the power converter circuit during operation.

17. The power supply of claim 16 , comprising one or more capacitors supported by the insulative support and electrically coupled to the plurality of plate-like DC bus elements.

18. The power supply of claim 17 , wherein the insulative support comprises one or more receptacles for receiving a respective capacitor, each receptacle fitting tightly around the respective capacitor for stabilizing the respective capacitor.

19. The power supply of claim 16 , wherein the power converter circuit comprises a buck converter.

20. The power supply of claim 16 , wherein the insulative support comprises upper and lower housings enclosing and electrically insulating the three rectifier modules, the plurality of plate-like DC bus elements, and the control circuit from each other.

Assignees

• Illinois Tool Works

Inventors

• Jochman Nathan J

Classifications

• H05K7/209

  Heat transfer by conduction from internal heat source to heat radiating structure (H05K7/20909 takes precedence) · CPC title

• B23K9/32

  Accessories · CPC title

• G05F1/02

  Regulating electric characteristics of arcs · CPC title

• H05K7/20

  Modifications to facilitate cooling, ventilating, or heating · CPC title

• H02M7/2173

  in a biphase or polyphase circuit arrangement (H02M7/2176 takes precedence; voltage multipliers H02M7/25) · CPC title