Methods and apparatus for providing welding power and preheating power

Abstract

An example welding power supply includes: a power input configured to receive alternating current (AC) input power; and a power conversion circuit system configured to: convert a first portion of the input power into welding power; output the welding power to a welding circuit; convert a second portion of the input power into preheating power; and output the preheating power to a preheater.

Description

[0001] Related applications

[0002] This patent claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 841,153, filed April 30, 2019, entitled “METHODS AND APPARATUS TOPROVIDE WELDING-TYPE POWER AND PREHEATING POWER”. The entire contents of U.S. Patent Application Serial No. 62 / 841,153 are expressly incorporated herein by reference. Background Technology

[0003] This disclosure relates generally to welding, and more specifically to methods and apparatus for converting welding power into welding power and resistance preheating power.

[0004] Welding is an increasingly prevalent process across all industries. Simply put, welding is a way to join two pieces of metal together. A wide variety of welding systems and welding control schemes have been implemented for various applications. In continuous welding operations, metal inert gas (MIG) and submerged arc (SAW) technologies allow for the formation of continuous weld beads by feeding a welding electrode wire protected by an inert gas from the welding torch and / or by flux. This wire feeding system can also be used in other welding systems, such as tungsten inert gas (TIG) welding. Electrical power is applied to the welding wire and the workpiece completes the circuit to maintain a welding arc that melts the electrode wire and the workpiece to form the desired weld. Summary of the Invention

[0005] A method and apparatus for providing welding power and preheating power are disclosed, substantially illustrated by at least one figure and described in conjunction with the at least one figure, as set forth more fully in the claims. Attached Figure Description

[0006] Figure 1 An example welding power supply according to various aspects of this disclosure is illustrated, which is configured to convert input power into welding power and preheating power.

[0007] Figure 2 It can be used to achieve Figure 1 A schematic diagram of an example power conversion circuit system.

[0008] Figure 3 The illustration shows another example welding system according to various aspects of the present disclosure, which is configured to convert input power into welding power and preheating power. The welding system includes a wire feeding assembly having a preheater within the housing of a welding power supply.

[0009] Figure 4 The illustration shows another example welding system according to various aspects of this disclosure, which is configured to convert input power into welding power and preheating power.

[0010] Figure 5 Another example welding system according to aspects of this disclosure is illustrated, which is configured to convert input power into welding power and preheating power, and includes a power bus configured to be coupled to welding terminals.

[0011] Figure 6 This is a flowchart representing example machine-readable instructions that can be generated by... Figure 1 , Figure 3 , Figure 4 and / or Figure 5 The example welding power supply performs to convert input power into welding power and preheating power.

[0012] Figure 7 The illustration shows another example welding power supply according to various aspects of this disclosure, which is configured to convert input power into welding power and preheating power.

[0013] The accompanying drawings are not necessarily drawn to scale. Where appropriate, similar or identical reference numerals are used to refer to similar or identical parts. Detailed Implementation

[0014] For the purpose of promoting an understanding of the principles of this disclosure, reference will now be made to the examples shown in the accompanying drawings, and these examples will be described using specific language. However, it should be understood that this disclosure is not intended to limit the scope of the claims. Modifications to the illustrated examples and such further applications of the principles of this disclosure as commonly conceived by those skilled in the art to which this disclosure pertains are envisioned.

[0015] This document discloses systems and methods for providing preheating power and welding power to a welding torch. In particular, the disclosed example systems include a welding power source configured to output welding power and preheating power to the welding torch for preheating the electrode wire prior to the arc. In some examples, one or more power conversion circuits are included within a single welding power source (which may also include a wire feed assembly) to generate and output both preheating power and welding power from a single power input.

[0016] While conventional preheating techniques involve control circuitry systems with multiple power sources and / or the ability to coordinate preheating and welding outputs to achieve effective welding results, the disclosed example systems and methods can reduce the complexity and / or cost involved in welding using wire preheating. For example, operators switching from conventional welding power sources to welding power sources that also provide preheating power can benefit from purchasing and using a single power source capable of outputting both welding and preheating power.

[0017] By providing both welding power and preheating power from a single power source, and in some examples providing wire feeding, the disclosed systems and methods enable welding operators to take advantage of the benefits of wire preheating, such as reduced heat input to the weld, increased cladding, reduced energy required for the process to transfer from droplets to spray transfer, and / or reduced hydrogen in the electrode wire and the resulting weld.

[0018] As used herein, the terms “circuit” and “circuit system” refer to physical electronic components (i.e., hardware) and any software and / or firmware (code) that can configure, be executed by, and / or otherwise associate with the hardware. As used herein, for example, a particular processor and memory may constitute a first “circuit” when executing a first set of one or more lines of code, and a second “circuit” when executing a second set of one or more lines of code. As used herein, “and / or” refers to any one or more items in the list connected by “and / or”. For example, “x and / or y” refers to any element in the three-element set {(x),(y),(x,y)}. In other words, “x and / or y” means “one or both of x and y”. As another example, “x, y, and / or z” refers to any element in the seven-element set {(x),(y),(z),(x,y),(x,z),(y,z),(x,y,z)}. In other words, “x, y, and / or z” means “one or more of x, y, and z”. As used herein, the term "exemplary" means used as a non-limiting example, instance, or paradigm. As used herein, the terms "e.g." and "for example" provide a list of one or more non-limiting examples, instances, or paradigms. As used herein, whenever a circuit system includes the hardware and code necessary (if required) to perform a function, the circuit system is "operable" to perform that function, the execution of which is disabled or not enabled (e.g., through operator-configurable settings, factory adjustments, etc.).

[0019] As used herein, a wire-feed welding system refers to a system capable of performing welding (e.g., gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), submerged arc welding (SAW), etc.), brazing, cladding, wear-resistant surfacing, and / or other processes, wherein filler metal is provided by a welding wire fed to the working position (e.g., an arc or weld pool).

[0020] As used herein, a welding power source refers to any device capable of supplying power for welding, cladding, plasma cutting, induction heating, laser processing (including laser welding and laser cladding), carbon arc cutting or scraping, and / or resistance preheating when power is applied, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, and their associated control circuitry and other auxiliary circuitry. The terms "power source" and "power supply" are used interchangeably herein.

[0021] As used in this article, preheating refers to heating the electrode wire before the welding arc and / or deposition along the path of the electrode wire.

[0022] Some published examples describe conducting current "from" certain locations in a circuit and / or power supply and / or conducting current "to" certain locations in a circuit and / or power supply. Similarly, some published examples describe "providing" current via one or more paths, which may include one or more conductive elements or partially conductive elements. The terms "from," "to," and "providing" used to describe current conduction do not require a direction or polarity of the current. Rather, even if an example current polarity or direction is provided or illustrated, for a given circuit, these currents may conduct in either direction or have either polarity.

[0023] The disclosed example welding power supply includes a power input configured to receive alternating current (AC) input power and a power conversion circuit system. The power conversion circuit system is configured to convert a first portion of the input power into welding power and output the welding power to a welding circuit, and to convert a second portion of the input power into preheating power and output the preheating power to a preheater.

[0024] Some example welding power supplies further include: a rectifier configured to rectify AC input power; and a pre-regulator circuit configured to convert the rectified AC input power into intermediate power, wherein a first portion and a second portion of the input power are received as intermediate power at a first power conversion circuit system and a second power conversion circuit system. In some example welding power supplies, the power conversion circuit system includes: a first power conversion circuit system configured to convert the first portion of the input power into welding power and output the welding power to a welding circuit; and a second power conversion circuit system configured to convert the second portion of the input power into preheating power and output the preheating power to a preheating circuit. In some examples, the first power conversion circuit system includes a first power converter and a first transformer, and the second power conversion circuit system includes a second power converter and a second transformer.

[0025] In some example welding power supplies, the power conversion circuit system includes: a rectifier configured to convert AC input power to a first DC bus having a first DC voltage; a first power conversion circuit system configured to convert the first DC voltage to a second DC voltage; a second power conversion circuit system configured to convert the second DC voltage to welding power at least via a first inverter and a first transformer, and output the welding power to a welding circuit; and a third power conversion circuit system configured to convert the second DC voltage to preheating power at least via a second inverter and a second transformer, and output the preheating power to a preheater.

[0026] Some example welding power supplies further include a first connector configured to output welding power; and a second connector configured to output preheating power. Some example welding power supplies further include a third connector configured to conduct at least one of welding power or preheating power. Some example welding power supplies further include: first and second terminals for outputting welding power; and a wire feeding assembly including a contact element configured as part of the preheater and conducting preheating power to an electrode wire fed by a wire feeder. In some examples, the contact element includes at least one of a wire feed roller or a idler roller.

[0027] Some example welding power supplies further include first and second welding terminals configured to output welding power, and a wire feeding assembly. The wire feeding assembly includes: a wire feed roller configured to feed an electrode wire to a third terminal connected to the welding power supply; a first power bus configured to be electrically connected to a second power bus of the third terminal when the third terminal is connected to the welding power supply, wherein a power conversion circuit system is configured to output preheating power via the first power bus and via the first or second welding terminal; and a third power bus configured to be electrically connected to a fourth power bus of the third terminal when the third terminal is connected to the welding power supply, the wire feeding assembly being configured to connect the first or second welding terminal to the third power bus such that welding power can be output to the welding circuitry.

[0028] In some examples, the power conversion circuit system includes multiple switch-mode power supplies. In some examples, the preheater includes at least one of the following: a preheating circuit including a portion of an electrode wire located between a first contact point and a second contact point; an induction coil configured to heat the electrode wire; a tungsten electrode configured to establish an arc to the electrode wire; a laser configured to output energy to the electrode wire; a heating coil configured to heat the electrode wire by radiation; or a convection heating material configured to contact the electrode wire to transfer heat to the electrode wire.

[0029] Some example welding power sources further include a control circuit system configured to control a power conversion circuit system to convert a first portion and a second portion of the input power. In some examples, the control circuit system is configured to determine at least one of the welding power to be output by the power conversion circuit system or the preheating power to be output by the power conversion circuit system based on welding process parameters. In some examples, the welding process parameters include at least one of workpiece thickness, workpiece material, wire material, wire type, wire diameter, gas type, or total heat input limit. In some examples, the control circuit system is configured to determine at least one of the welding voltage, welding current, wire feed speed, inductance, welding pulse width, relative pulse amplitude, waveform, preheating voltage, preheating current, preheating pulse, preheating resistance, or preheating energy input based on the welding process parameters.

[0030] Figure 1 An example welding system 10 is illustrated, which includes a welding power source 12 configured to convert input power into welding power and preheating power. Figure 1The example welding system 10 includes a welding power source 12 and a preheating welding torch 14. The welding torch 14 can be configured for any wire-feed welding process based on the desired welding application, such as gas metal arc welding (GMAW), flux-cored wire arc welding (FCAW), self-shielded FCAW, and / or submerged arc welding (SAW).

[0031] The welding power source 12 converts the input power of the self-powered power source 22 into one or both of the output welding power and / or preheating power that are output to the welding torch 14. Figure 1 In the example, the welding power source also supplies filler metal to the welding torch 14, which is configured for GMAW welding, FCAW welding, or SAW welding.

[0032] Welding power source 12 is connected to or includes a main power source 22, such as a power grid supplying the main power or an engine-driven generator, which can be a single-phase or three-phase AC power source. For example, welding power source 12 can be an engine-driven welding power source that includes an engine and generator within welding power source 12 to provide the main power 22. Welding power source 12 can process the main power 22 to output welding-type power for output to welding torch 14 via welding torch cable 50.

[0033] The power conversion circuit system 30 converts primary power (e.g., AC power) into welding-type power as direct current (DC) or AC, and into preheating power. Example preheating power may include DC and / or AC current that provides resistance heating or Joule heating when conducted through a portion of electrode wire 54. Additional examples of preheating power disclosed herein may include high-frequency AC current providing induction heating within electrode wire 54, and / or power suitable for hot-wire technology, arc-based preheating (where an arc is used to apply heat to the welding wire prior to the welding arc), laser-based preheating, radiant heating, convection heating, and / or any other form of welding wire heating. The power conversion circuit system 30 may include circuit elements such as transformers, switches, boost converters, inverters, buck converters, half-bridge converters, full-bridge converters, forward converters, reverse converters, internal buses, bus capacitors, voltage and current sensors, and / or any other topology and / or circuitry for converting input power into welding power and preheating power and outputting the welding power and preheating power to welding torch 14. The following provides a more detailed example implementation of the power conversion circuit system 30.

[0034] The first and second portions of the input power can be divided by time (e.g., the first portion is used at a first time, and the second portion is used at a second time) and / or divided into a portion of the total delivered power at a given time. The power conversion circuit system 30 outputs welding power to the welding circuit and preheating power to the preheating circuit or other preheater. The welding circuit and preheating circuit can be implemented using any combination of the welding torch 14, welding accessories, and / or the power supply 12.

[0035] The power conversion circuit system 30 may include circuit elements such as a boost converter. In some examples, the primary power 22 received by the power conversion circuit system 30 is an AC voltage between approximately 110V and 575V, approximately 110V and 480V, or approximately 110V and 240V. As used with reference to input power, the term "approximately" may refer to within ±5 volts or 10% of the desired voltage.

[0036] The power conversion circuit system 30 can be configured to convert input power into any conventional and / or future welding-type output. Example power conversion circuit system 30 can implement one or more controlled voltage control loops, one or more controlled current control loops, one or more controlled power control loops, and / or one or more controlled resistance control loops to control the voltage and / or current output to the welding circuit and / or to the preheating circuit. As described in more detail below, the power conversion circuit system 30 can be implemented using one or more conversion circuits (e.g., multiple conversion circuits), in which a single conversion circuit is used to generate each of the welding-type output and the preheating output.

[0037] In some examples, the power conversion circuitry system 30 is configured to convert input power into a controlled waveform welding output, such as for pulsed welding processes or short-circuit welding processes (e.g., metal deposition control (RMD)). TM For example, RMD TM The welding process utilizes a controlled waveform welding output, the current waveform of which changes at specific points in time within the short-circuit cycle.

[0038] The welding power source 12 includes a control circuit system 32 and an operator interface 34. The control circuit system 32 controls the operation of the welding power source 12 and can receive input from the operator interface 34, through which the operator can select the welding process (e.g., GMAW, FCAW, SAW) and input the required input power parameters (e.g., voltage, current, specific pulse or non-pulse welding scheme, etc.). The control circuit system 32 can be configured to receive and process multiple inputs regarding the performance and requirements of the system 10.

[0039] The control circuitry system 32 includes one or more controllers and / or processors 36 that control the operation of the power supply 12. The control circuitry system 32 receives and processes multiple inputs associated with the system's performance and requirements. The processors 36 may include one or more microprocessors, such as one or more "general-purpose" microprocessors, one or more dedicated microprocessors and / or ASICs, one or more microcontrollers, and / or any other type of processing and / or logic device. For example, the control circuitry system 32 may include one or more digital signal processors (DSPs). The control circuitry system 32 may include circuitry systems such as relay circuitry systems, voltage and current sensing circuitry systems, power storage circuitry systems, and / or other circuitry systems, and is configured to sense the primary power 22 received by the power supply 12.

[0040] Example control circuitry system 32 includes one or more memory devices 38. The memory devices 38 may include volatile and / or non-volatile memory and / or storage devices such as random access memory (RAM), read-only memory (ROM), flash memory, hard disk drive, solid-state storage devices, and / or any other suitable optical, magnetic, and / or solid-state storage media. The memory devices 38 store data (e.g., data corresponding to a welding application), instructions (e.g., software or firmware for performing the welding process), and / or any other suitable data. Examples of stored data for welding applications include torch orientation (e.g., orientation), distance between the contact tip and the workpiece, voltage, current, welding apparatus settings, etc. Memory devices 38 may store machine-executable instructions (e.g., firmware or software) for execution by processor 36. Additionally or alternatively, one or more control schemes for different welding processes, along with associated settings and parameters, may be stored in the memory devices 38 along with machine-executable instructions configured to provide specific outputs during operation (e.g., initiating wire feed, enabling gas flow, capturing welding current data, detecting short-circuit parameters, determining the amount of spatter).

[0041] The example operator interface 34 enables the control or adjustment of parameters of the welding system 10. Operator interface 34 is connected to control circuitry 32 to allow the operator to select and adjust the welding process (e.g., pulse, short-circuit, FCAW) by choosing wire size, wire type, material, and gas parameters. Operator interface 34 is also connected to control circuitry 32 to control voltage, amperage, power, resistance, wire feed speed, and arc length for the welding application. Operator interface 34 can receive input using any input device, such as a keypad, keyboard, buttons, touchscreen, voice activation system, wireless device, etc.

[0042] The operator interface 34 can receive inputs specifying workpiece thickness, workpiece material, welding wire material (e.g., steel, aluminum), welding wire type (e.g., solid, cored), welding wire diameter, gas type, and / or any other parameters. Upon receiving the input, the control circuitry 32 determines the welding output for the welding application. For example, the control circuitry 32 can determine the welding voltage, welding current, wire feed speed, inductance, welding pulse width, relative pulse amplitude, waveform, preheating voltage, preheating current, preheating pulse, preheating resistance, preheating energy input, and / or any other welding and / or preheating parameters for the welding process, based at least in part on the input received through the operator interface 34.

[0043] In some examples, the welding power source 12 may include a polarity reversal circuitry. The polarity reversal circuitry reverses the polarity of the output welding power when instructed by the control circuitry 32. For example, some welding processes (such as TIG welding) can achieve the desired weld when the electrodes have a negative polarity (referred to as DC electrode negative) (DCEN). Other welding processes (such as bond welding or GMAW welding) can achieve the desired weld when the electrodes have a positive polarity (referred to as DC electrode positive) (DCEP). When switching between TIG welding and GMAW welding processes, the polarity reversal circuitry can be configured to switch the polarity from DCEN to DCEP.

[0044] Alternatively, the operator may simply connect the welding torch 14 to the power supply 12 without knowing the polarity, such as when the welding torch is located at a considerable distance from the power supply 12. The control circuit system 32 may instruct the polarity reversal circuit system to reverse the polarity in response to signals received via the communication circuit system and / or based on the selected or determined welding process.

[0045] In some examples, power supply 12 includes a communication circuitry. For example, the communication circuitry may be configured to communicate with welding torch 14, accessories, and / or other devices connected to power cables and / or communication ports. The communication circuitry sends and receives commands and / or feedback signals via a welding power cable used to supply welding power. Alternatively or additionally, the communication circuitry may communicate wirelessly with welding torch 14 and / or other devices.

[0046] For some welding processes (e.g., GMAW), a shielding gas is used during the welding process. Figure 1In one example, the welding power source 12 includes one or more gas control valves 46 configured to control the flow rate of gas from the gas source 48. The control circuitry 32 controls the gas control valves 46. The welding power source 12 may be coupled to one or more gas sources 48, because, for example, some welding processes may utilize shielding gases different from those used in other welding processes. In some examples, the welding power source 12 is configured to supply gas and welding power and / or preheating power together to the welding torch 14 via a combined welding torch cable 50. In other examples, the gas control valves 46 and the gas sources 48 may be separate from the welding power source 12. For example, the gas control valves 46 may be configured to connect to the combined welding torch cable 50 via a connector.

[0047] Example power supply 12 includes a wire feed assembly 60 that supplies electrode wire 54 to welding torch 14 for welding operations. The wire feed assembly 60 includes elements such as a wire spool 64 and a wire feed driver configured to power drive roller 68. The wire feed assembly 60 feeds the electrode wire 54 to welding torch 14 along welding torch cable 50. Welding output can be supplied via welding torch cable 50 coupled to welding torch 14 and / or working cable 42 coupled to workpiece 44. As disclosed in more detail below, preheating output can be supplied to welding torch 14 (or via a connection in the wire feed assembly 60 to another component), supplied to welding torch 14 via one or more preheating power terminals, and / or supplied to a preheater within the wire feed assembly 60 or within the housing 86 of welding power supply 12.

[0048] Example power supply 12 is connected to a preheated GMAW torch 14, which is configured to supply gas, electrode wire 54, and electrical power to the welding application. As discussed in more detail below, welding power supply 12 is configured to receive input power, convert a first portion of the input power into welding power and output the welding power to the welding circuit, and convert a second portion of the input power into preheating power and output the preheating power to the preheating circuit or other preheater.

[0049] The example welding torch 14 includes a first contact end 18 and a second contact end 20. An electrode wire 54 is fed from a wire feed assembly 60 to the welding torch 14 and passes through the contact ends 18 and 20 to generate a welding arc 26 between the electrode wire 54 and the workpiece 44. The preheating circuit includes the first contact end 18, the second contact end 20, and a portion 56 of the electrode wire 54 located between the first contact end 18 and the second contact end 20. The example power supply 12 is further connected to a working cable 42, which is connected to the workpiece 44.

[0050] During operation, the electrode wire 54 passes through the second contact end 20 and the first contact end 18. Between the second contact end and the first contact end, the power conversion circuit system 30 outputs a preheating current to heat the electrode wire 54. Specifically, in Figure 1 In the configuration shown, the preheating current enters the electrode wire 54 via the second contact end 20 and exits the electrode wire 54 via the first contact end 18. However, the preheating current can be conducted in the opposite direction. At the first contact end 18, the welding current can also enter (or exit) the electrode wire 54.

[0051] The welding current is output from the power conversion circuit system 30, which obtains preheating and welding power from the main power supply 22. The welding current leaves the electrode wire 54 via the workpiece 44, thereby generating a welding arc 26. When the electrode wire 54 contacts the workpiece 44, the circuit is completed, and the welding current flows through the electrode wire 54, through (multiple) metal workpieces 44, and returns to the power conversion circuit system 30 via the working cable 42. The welding current melts the electrode wire 54 and the base metal of (multiple) workpieces 44 in contact with the electrode wire 54, thereby joining the multiple workpieces together as the melt solidifies. By preheating the electrode wire 54, a welding arc 26 can be generated with a greatly reduced arc energy. Generally, the preheating current is proportional to the distance between the contact ends 18, 20 and the electrode wire 54.

[0052] During operation, the power conversion circuit system 30 establishes a preheating circuit to conduct preheating current through a segment 56 of the electrode wire 54. The preheating current flows from the power conversion circuit system 30 to the second contact terminal 20 via the first conductor 102, through the segment 56 of the electrode wire 54 to the first contact terminal 18, and returns to the power conversion circuit system 30 via a second cable 104 connecting the power conversion circuit system 30 to the first contact terminal 18. Either or both of conductors 102 and 104 may be combined with other cables and / or conduits, or may not be combined with them. For example, conductors 102 and / or 104 may be part of cable 50. In other examples, conductor 104 is included within cable 50, and conductor 102 leads separately to the welding torch 14. For this purpose, the power supply 12 may include one to three terminals to which one or more cables may be physically connected to establish preheating connections, welding connections, and working connections. For example, multiple connections may be implemented in a single terminal using appropriate insulation between the different connections.

[0053] exist Figure 1 In the example shown, power supply 12 includes two terminals 106 and 108 configured to output welding power to contact tip 20 and working cable 42. Conductor 104 connects terminal 106 to welding torch 14, which supplies power from conductor 104 to contact tip 20. Working cable 42 connects terminal 108 to workpiece 44. Example terminals 106 and 108 may have a specified polarity or may have reversible polarity.

[0054] Because the preheating current path overlaps with the welding current path at the connection between the first contact terminal 18 and the power conversion circuit system 30 (e.g., via conductor 104), the cable 50 can achieve a more cost-effective single connection (e.g., a single cable) between the first contact terminal 18 and the power conversion circuit system 30, rather than providing separate connections for the welding current flowing to the first contact terminal 18 and the preheating current flowing to the first contact terminal 18.

[0055] Example power supply 12 includes a housing 86, within which a control circuit system 32, a power conversion circuit system 30, a wire feed assembly 60, an operator interface 34, and / or a gas control valve 46 are housed. In an example where the power conversion circuit system 30 includes multiple power conversion circuits (e.g., a preheating power conversion circuit and a welding power conversion circuit), all power conversion circuits are included within the housing 86.

[0056] Figure 2 This is a schematic diagram of an example power conversion circuit system 200, which can be used to implement... Figure 1 The power conversion circuit system 30 is used to convert input power to output welding power and preheating power.

[0057] Figure 2 The example power conversion circuit system 200 includes a preheating power conversion circuit system 202 and a welding power conversion circuit system 204. Both the preheating power conversion circuit system 202 and the welding power conversion circuit system 204 are connected to the main power source 22, which serves as the input power source. Figure 2 In the example, the primary power 22 is single-phase AC power. The power conversion circuit system 200 includes a rectifier 206 that rectifies the AC input power to provide a first DC bus voltage 208.

[0058] Boost converter 210 can be used to convert the first DC bus voltage 208 into a desired second DC bus voltage 212. Boost converter 210 can implement a pre-regulator circuit to convert rectified power (e.g., the first DC bus voltage) into intermediate power (e.g., the second DC bus voltage 212). In other examples, each of the preheating power conversion circuit system 202 and the welding power conversion circuit system 204 can be supplied with different DC voltages using different boost converters, and / or boost converter 210 can supply separate DC buses (with corresponding energy storage elements) to supply different DC input voltages to each of the preheating power conversion circuit system 202 and the welding power conversion circuit system 204 at different time periods. The preheating power conversion circuit system 202 and the welding power conversion circuit system 204 share the same input power source (e.g., main power 22), even though the input power can be partitioned between the preheating power conversion circuit system 202 and the welding power conversion circuit system 204 in any suitable manner.

[0059] The preheating power conversion circuit system 202 converts the second DC bus voltage 212 into a preheating output 214, and the welding power conversion circuit system 204 converts the second DC bus voltage 212 into a welding output 216. Each of the example preheating output 214 and welding output 216 is generated using different combinations of inverters and / or transformers (e.g., a first transformer in the preheating power conversion circuit system 202 and a second transformer in the welding power conversion circuit system 204).

[0060] Example control circuit system 32 controls switches Q1, Q2, Q3, Q4, and Q5 in example preheating power conversion circuit system 202, example welding power conversion circuit system 204, and example boost converter 210. By controlling switches Q1-Q5, the example control circuit system can control the second DC bus voltage 212, preheating output 214, and / or welding output 216 to output preheating output 214 and / or welding output 216 according to configured preheating parameters (e.g., preheating voltage, preheating current, etc.) and / or configured welding parameters (e.g., welding voltage, welding current, pulse parameters, AC frequency, etc.).

[0061] like Figure 2As shown, the example preheating power conversion circuit system 202 and the welding power conversion circuit system 204 are each a forward converter that converts the first DC bus into an output. Although the example preheating power conversion circuit system 202 and the example welding power conversion circuit system 204 are described herein as forward converter circuits, any one or both of the preheating power conversion circuit system 202 and the welding power conversion circuit system 204 can be implemented using any other topology, such as a switch-mode power supply, a full-bridge and / or half-bridge topology, and / or an inverter-based converter circuit.

[0062] The control circuit system 32, operator interface 34, gas control valve 46 and / or wire feeding assembly 60 may be powered by preheating output 214, welding output 216 and / or one or more additional and / or different power conversion circuits that can convert one or more portions of the main power 22.

[0063] In some examples, control circuitry 32 is configured to regulate the control of welding power conversion circuitry 204 to adjust welding output 216 based on preheating output, such as maintaining a consistent welding heat input and / or increasing cladding. For example, control circuitry 32 may reduce welding output 216 (e.g., welding voltage and / or welding current) via welding power conversion circuitry 204 based on increasing preheating output 214 controlled by preheating power conversion circuitry 202.

[0064] Figure 3 Another example welding power source 300 is illustrated, which is configured to convert input power (e.g., main power 22) into welding power (e.g., welding output 216) and preheating power (e.g., preheating output 214). The example welding power source 300 includes a power conversion circuitry 30, a control circuitry 32, an operator interface 34, a plurality of processors 36, a memory 38, a gas control valve 46, a housing 86, and terminals 106, 108. The example power source 300 receives the main power 22 as input power to the power conversion circuitry 30.

[0065] The example welding power source 300 further includes a wire feeding assembly 302, which can be similar to... Figure 1 The wire feeding assembly 60 includes a wire spool 64, a wire feeding driver, and a drive roller 68. Example wire feeding assembly 302 further includes a wire preheater 304 (i.e., within the same housing 86 as the power conversion circuit system 30, where the welding power source 300 is located).

[0066] exist Figure 3In the example, the power conversion circuit system 30 outputs a preheating output 214 to a wire preheater 304 within the housing 86 (e.g., within the wire feed assembly 302). The example wire preheater 304 may provide any of the following: resistance preheating (e.g., via two contact points on the electrode wire 54), induction heating of the electrode wire 54 (e.g., via routing the electrode wire 54 through or near an induction coil), arc-based preheating (e.g., via one or more tungsten electrodes configured to establish an arc on the electrode wire 54), laser-based preheating (e.g., via a laser configured to output energy to the wire 54), radiative heating (e.g., via a heating coil not in contact with the wire 54 but configured to heat the wire 54 by radiation), convection heating (e.g., via a heating coil configured to contact the wire 54 to transfer heat to the wire 54, ceramic, or other heat-receiving material), and / or any other preheating technique. In operation, the example welding power source 300 preheats the electrode wire 54 via the wire preheater 304. The example control circuit system 32 can be referenced above. Figure 1 and Figure 2 The power conversion circuit system 30 is controlled as described.

[0067] As an example, the preheater 304 may provide a first contact point instead of a second contact end 20, such that the resistively preheated portion of the electrode wire 54 extends from the preheater 304 to the contact end 18. Example: the preheater 304 may be a drive roller or idle roller of the wire feed assembly 302.

[0068] By performing preheating at power supply 300, the operator can use a standard welding torch instead of one that includes preheating and / or liquid cooling equipment. Therefore, performing preheating at power supply 300 reduces the size of the welding torch that the operator needs to hold and manipulate.

[0069] In other examples, other types of wire preheaters may be included in the preheating torch 14. For example, Figure 4 This is a block diagram of an example welding power supply 400 that provides preheating power (e.g., preheating output 314) to the wire preheater 402 in the welding torch 14. The example welding power supply 400 includes a power conversion circuit system 30, a control circuit system 32, an operator interface 34, multiple processors 36, a memory 38, a gas control valve 46, and a housing 86. The example power supply 400 receives primary power 22 as input power to the power conversion circuit system 30.

[0070] exist Figure 4In this example, power conversion circuitry 30 outputs preheating output 214 to wire preheater 402 in welding torch 14. Example wire preheater 402 can provide any of the following: induction heating of electrode wire 54 (e.g., via routing electrode wire 54 through or near an induction coil), arc-based preheating (e.g., via one or more tungsten electrodes configured to establish an arc on electrode wire 54), laser-based preheating, radiative heating, convection heating, and / or any other preheating technique. In operation, example power supply 12 preheats electrode wire 54 via wire preheater 402 in welding torch 14. Example control circuitry 32 can be referenced above. Figure 4 The power conversion circuit system 30 is controlled as described.

[0071] In some other examples, the wire preheater 402 may be located in (e.g., integral with or attached to) the cable whip to which the welding torch 14 is attached to the wire feeder 16. For example, the cable may have a housing located midway along the cable whip, which is far enough away from the torch body (e.g., the handheld portion of the torch 14) that the mass of the wire preheater 402 does not significantly affect the operator's manipulation of the torch 14 during welding operations.

[0072] To provide preheating output 214 and welding output 216 to welding torch 14, the example power supply 400 further includes output terminals or connectors 404, 406, 408. Power conversion circuitry 30 outputs welding output 216 to workpiece 44 and contact tip 18 via terminals 404, 406, and outputs preheating output 214 to wire preheater 402 via terminals 406, 408. Instead of using terminal 406 for both welding output 216 and preheating output 214, the power supply 400 may include an additional output terminal for outputting preheating output 214.

[0073] Figure 5 Another example welding power source 500 is illustrated, which is configured to convert input power into welding power (e.g., welding output 216) and preheating power (e.g., preheating output 214). The example welding power source 500 includes a power conversion circuitry 30, a control circuitry 32, an operator interface 34, a plurality of processors 36, a memory 38, a gas control valve 46, and a housing 86. The example power source 500 receives primary power 22 as input power to the power conversion circuitry 30 and outputs preheating output 214 and welding output 216 to the contact tips 18, 20 of the preheating torch 14.

[0074] To connect the welding torch 14 to the power supply 500, the example welding power supply 500 further includes a welding torch terminal 502, a preheating power bus 504, and a welding power bus 506. The welding torch terminal 502 is configured to receive a complementary welding torch connector 508 connected to the welding torch 14 via a welding torch cable 50. When connected, the welding torch terminal 502 and the welding torch connector 508 conduct preheating output 214 and welding output 216 to the welding torch 14. The power supply 500 further includes welding output terminals 510 and 512. For example, the power conversion circuit system 30 is configured to output preheating output 214 via the preheating power bus 504 and output terminal 510, and is configured to output welding output 216 via welding output terminals 510 and 512.

[0075] To control the polarity of the welding output, the welding power bus 506 can be connected to either of the welding output terminals 510 and 512 via bus terminal 514 and short cable whip 516. The example power bus 506 can have corresponding polarities by connecting the short cable whip 516 to one of terminals 510 and 512 and the working cable 42 to the other of terminals 510 and 512. Regardless of the polarity of the welding output 216 to the welding torch 14, the preheating output 214 is configured to output preheating output 214 via the preheating power bus 504 and one of the welding output terminals 510 and 512.

[0076] An exemplary implementation of the welding torch terminal 502, the welding torch connector 508, and the power bus of the welding torch terminal 502 and the welding torch connector 508 (which can be used to implement the preheating power bus 504 and / or the welding power bus 506) is disclosed in U.S. Patent No. 9,610,646, issued April 4, 2017, to Romenesko et al. The entire contents of U.S. Patent No. 9,610,646 are incorporated herein by reference. However, other connectors and / or terminals may be used to transmit welding current and / or preheating current to the welding torch 14. Figure 5 In the example, both the preheating power bus 504 and the welding power bus 506 are connected to the welding torch 14 via the welding torch cable 50.

[0077] Although the foregoing examples are described with reference to the resistive preheating of the welding wire at the welding torch, the disclosed examples can also be used in conjunction with other forms of wire heating, such as induction heating of the welding wire, hot wire technology, arc-based preheating (where heat is applied to the welding wire using an arc before the welding arc), laser-based preheating, radiation heating, convection heating, and / or any other form of wire heating.

[0078] Figure 6 This is a flowchart illustrating example machine-readable instructions that can be generated by... Figure 1 , Figure 3 , Figure 4 and / or Figure 5 The example welding power source is executed to convert the input power into welding power and preheating power. See below for reference. Figure 1 Welding power source 12 and Figure 2 The example power conversion circuit system 200 describes example instruction 600. However, instruction 600 can be executed using other implementations of the welding power supply 12, power conversion circuit system 30, and / or other welding accessories.

[0079] At box 602, the control circuit system 32 determines whether input to specified welding process parameters(s) has been received. For example, the control circuit system 32 may receive input to any one or more of the specified welding process parameters(s), including workpiece thickness, workpiece material, wire material, wire type, wire diameter, gas type, or total heat input limit. Alternatively or additionally, the control circuit system 32 may receive welding parameters (e.g., welding voltage, welding current, wire feed speed, pulse parameters, welding gas flow rate, etc.), preheating parameters (e.g., preheating voltage, preheating current, preheating temperature, preheating resistance, preheating heat input), total heat input, and / or any other parameters as input. The control circuit system 32 may be connected via... Figure 1 The operator interface 34 receives input from the input device on the welding torch 14, via welding accessories and / or any other input means.

[0080] If input has been received (box 602), then in box 604, the control circuit system 32 determines the welding power output and / or preheating power output based on the received welding process parameters. For example, the control circuit system 32 may determine one or more of the following: welding voltage, welding current, wire feed speed, inductance, welding pulse width, relative pulse amplitude, waveform, preheating voltage, preheating current, preheating pulse, preheating resistance, preheating energy input, and / or any other welding power parameter and / or preheating power parameter.

[0081] After determining the welding power output and / or preheating power output (box 604), or if no input has been received (box 602), the control circuitry 32 determines in box 606 whether the welding is valid. For example, the control circuitry 32 may determine whether a trigger has been pressed on the welding torch 14 and / or whether welding power is available at the input of the power conversion circuitry 30. If the welding is invalid (box 606), control returns to box 602 to wait for input.

[0082] When the soldering is effective (box 606), at box 608, the power conversion circuit system 30 receives power input (e.g., Figure 1The main power 22). At block 610, the control circuit system 32 determines whether to enable the welding output (e.g., based on welding process parameters). If the welding output is enabled (block 610), then at block 612, the power conversion circuit system 30 converts at least a portion of the input power into a welding power output based on the determined welding power output. For example, the control circuit system 32 can control Figure 2 The welding power conversion circuit system 204 and / or boost converter 210 convert the main power 22 into welding output 216.

[0083] In block 614, the power conversion circuit system 30 outputs welding output 216 to welding torch 14. For example, welding output 216 is conducted to contact tip 18 and working cable 42 to generate arc 26.

[0084] After outputting welding power (block 614), or if welding output is disabled (block 610), then in block 616, the control circuitry 32 determines whether to enable preheating (e.g., based on welding process parameters). For example, the control circuitry 32 can selectively enable the preheating power conversion circuitry 202 to provide preheating output 214, and selectively disable the preheating power conversion circuitry 202 to stop preheating output 214. The control circuitry 32 can enable and / or disable preheating based on, for example, user input via operator interface 34 and / or input from power supply, remote control, and / or welding torch 14.

[0085] If welding output is permitted (box 616), then at box 618, the power conversion circuitry 30 converts at least a portion of the input power into a preheating power output based on the determined preheating power output. For example, the control circuitry 32 can control... Figure 2 The preheating power conversion circuit system 202 and / or boost converter 210 convert the main power 22 into preheating output 214.

[0086] In block 620, the power conversion circuit system 30 outputs welding power to the welding torch 14. For example, preheating output 314 is conducted to contact tip 18 and contact tip 20 via conductors 102, 104.

[0087] After the preheating power is output (box 620), or if preheating is disabled (box 616), control returns to box 606 to determine whether the welding is still valid.

[0088] Figure 7 Another example welding power supply 700 is illustrated, which is configured to supply input power (e.g., Figure 1The primary power 22 is converted into welding power and preheating power. An example welding power supply 700 includes a control circuit system 32, an operator interface 34, multiple processors 36, a memory 38, a gas control valve 46, a housing 86, and terminals 106, 108. The example power supply 700 receives the primary power 22 as input power.

[0089] Instead of the power conversion circuitry 30 that converts the main power 22 into both preheating output 214 and welding output 216, the example welding power supply 700 includes a welding power conversion circuitry 702 and a preheating power conversion circuitry 704. The welding power conversion circuitry 702 receives the main power 22 and converts it into a welding output (e.g., welding output 216) based on a setpoint determined by the control circuitry 32. The welding power conversion circuitry 702 can be used with... Figure 2 The welding power conversion circuit system 204 may be similar, identical, or different. As an example, the welding power conversion circuit system 702 may include a rectifier 206, a boost converter 210, and the welding power conversion circuit system 204. In other examples, the welding power conversion circuit system 702 may include any other suitable topology. The welding power conversion circuit system 702 outputs welding output power to terminals 106 and 108.

[0090] Example preheating power conversion circuit system 704 obtains input power from the welding output of welding power conversion circuit system 702 (e.g., from connections to terminals 106, 108). Preheating power conversion circuit system 704 converts a portion of the welding power into a preheating output (e.g., preheating output 214), while the remaining welding power can be output to welding torch 14 and / or to wire feed assembly 60. Preheating power conversion circuit system 704 can be integrated with... Figure 2 The preheating power conversion circuit system 704 may be similar to, the same as, or different from the preheating power conversion circuit system 202. As an example, the preheating power conversion circuit system 704 may include a rectifier 206, a boost converter 210, and the preheating power conversion circuit system 202. In other examples, the preheating power conversion circuit system 704 may include any other suitable topology. The preheating power conversion circuit system 704 outputs welding preheating power to the welding torch 14 and / or to another preheater (e.g., similar to...). Figure 3 (The preheater 304 is the preheater). For example, the preheating power conversion circuit system 704 can output welding preheating power via conductor 706 in the welding torch cable 50 and via terminal 106.

[0091] This apparatus and / or method can be implemented in hardware, software, or a combination of hardware and software. The method and / or system can be implemented centrally in at least one computing system, processor, and / or other logic circuitry, or distributed with different elements spread across several interconnected computing systems, processors, and / or other logic circuitry. Any kind of computing system or other apparatus suitable for performing the methods described herein is appropriate. A typical combination of hardware and software may be a processing system having a program or other code integrated into a welding power supply, which, when loaded and executed, controls the welding power supply to perform the methods described herein. Another typical implementation may include application-specific integrated circuits or chips, such as field-programmable gate arrays (FPGAs), programmable logic devices (PLDs), or complex programmable logic devices (CPLDs) and / or system-on-a-chip (SoCs). Some implementations may include non-transitory machine-readable (e.g., computer-readable) media (e.g., flash memory, optical discs, magnetic disks, etc.) storing one or more lines of code executable by a machine, thereby enabling the machine to perform the processes described herein. As used herein, the term “non-transitory computer-readable medium” is defined to include all types of machine-readable storage media and excludes propagation signals.

[0092] Example control circuit implementations can be microcontrollers, field-programmable logic circuits, and / or any other control or logic circuits capable of executing instructions from the welding control software. Control circuits can also be implemented using analog circuits and / or a combination of digital and analog circuits.

[0093] Although this method and / or system has been described with reference to certain embodiments, those skilled in the art will understand that various changes and substitutions can be made without departing from the scope of this method and / or system. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the scope of this disclosure. For example, the blocks and / or components of the disclosed examples can be combined, divided, rearranged, and / or otherwise modified. Therefore, this method and / or system is not limited to the specific implementations disclosed. Instead, this method and / or system will include all implementations that are literally and under the doctrine of equivalents within the scope of the appended claims.

Claims

1. A welding power supply, comprising: Power input, which is configured to receive AC input power; as well as A power conversion circuit system, wherein the power conversion circuit system is configured as follows: The first part of the input power is converted into welding power; The welding power is output to the welding circuit; The second part of the input power is converted into preheating power; as well as The preheating power is output to the preheater. The power conversion circuit system includes: A first power conversion circuit system, configured to convert a first portion of the input power into the welding power and output the welding power to the welding circuit; and A second power conversion circuit system is configured to convert the second portion of the input power into the preheating power and output the preheating power to the preheater. The first power conversion circuit system and the second power conversion circuit system are separate circuit systems, and the conversion of the first part of the input power into the welding power by the first power conversion circuit system and the conversion of the second part of the input power into the preheating power by the second power conversion circuit system are independent of each other.

2. The welding power supply as claimed in claim 1, further comprising: A rectifier configured to rectify the AC input power; as well as A pre-regulator circuit, configured to convert rectified AC input power into intermediate power. The first and second portions of the input power are received as intermediate power at the first and second power conversion circuit systems, respectively.

3. The welding power supply as described in claim 1, wherein, The first power conversion circuit system includes a first power converter and a first transformer, and the second power conversion circuit system includes a second power converter and a second transformer.

4. The welding power supply as claimed in claim 1, wherein, The power conversion circuit system includes: A rectifier configured to convert the AC input power to a first DC bus having a first DC voltage; A first power conversion circuit system, the first power conversion circuit system being configured to convert the first DC voltage into a second DC voltage; A second power conversion circuit system, configured to convert the second DC voltage into the welding power via at least a first inverter and a first transformer, and output the welding power to the welding circuit; and A third power conversion circuit system is configured to convert the second DC voltage into the preheating power via at least a second inverter and a second transformer, and output the preheating power to the preheater.

5. The welding power supply as claimed in claim 1, further comprising: A first connector, configured to output the welding power; And a second connector configured to output the preheating power.

6. The welding power supply as claimed in claim 5, further comprising: A third connector is configured to conduct at least one of the welding power or the preheating power.

7. The welding power supply as claimed in claim 1, further comprising: A first terminal and a second terminal, wherein the first terminal and the second terminal are used to output the welding power; as well as A wire feeding assembly, the wire feeding assembly including a contact element configured as part of the preheater and transmitting the preheating power to the electrode wire fed by the wire feeder.

8. The welding power supply as claimed in claim 7, wherein, The contact element includes at least one of a wire feed roller or a idle roller.

9. The welding power supply as claimed in claim 1, further comprising: A first welding terminal and a second welding terminal are configured to output the welding power; as well as The wire feeding assembly includes: A wire feed roller, configured to feed an electrode wire to a third terminal connected to the welding power supply; A first power bus, configured to be electrically connected to a second power bus at the third terminal, the power conversion circuit system configured to output the preheating power via the first power bus and via the first welding terminal or the second welding terminal; and A third power bus, configured to be electrically connected to a fourth power bus of the third terminal, and the wire feeding assembly configured to connect the first welding terminal or the second welding terminal to the third power bus so that the welding power can be output to the welding circuit.

10. The welding power supply as claimed in claim 1, wherein, The power conversion circuit system includes multiple switch-mode power supplies.

11. The welding power supply as claimed in claim 1, wherein, The preheater includes at least one of the following: a preheating circuit, the preheating circuit including a portion of an electrode wire located between a first contact point and a second contact point; and an induction coil configured to heat the electrode wire. A tungsten electrode, the tungsten electrode being configured to establish an electric arc to the electrode wire; A laser configured to output energy to the electrode filament; A heating coil configured to heat the electrode wire by radiation; Alternatively, a convection heating material may be used, which is configured to contact the electrode wire to transfer heat to the electrode wire.

12. The welding power supply of claim 1, further comprising a control circuit system configured to control the power conversion circuit system to convert the first portion of the input power and the second portion of the input power.

13. The welding power supply as claimed in claim 12, wherein, The control circuit system is configured to determine, based on welding process parameters, the welding power to be output by the power conversion circuit system or the preheating power to be output by the power conversion circuit system.

14. The welding power supply as claimed in claim 13, wherein, The welding process parameters include at least one of the following: workpiece thickness, workpiece material, welding wire material, welding wire type, welding wire diameter, gas type, or total heat input limit.

15. The welding power supply as claimed in claim 13, wherein, The control circuit system is configured to determine at least one of the following based on the welding process parameters: welding voltage, welding current, wire feed speed, inductance, welding pulse width, relative pulse amplitude, waveform, preheating voltage, preheating current, preheating pulse, preheating resistance, or preheating energy input.

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