Method and apparatus for mechanically coupling an electric motor to an electrically isolating pump

Abstract

An electrically isolated pump system is provided, comprising: a welding-type power conversion circuit configured to convert input power into welding-type power; an electric motor configured to output mechanical power using an electric motor voltage obtained from the input power by the electric motor power conversion circuit; and an electrically insulating isolation connector configured to transmit the mechanical power to the pump, wherein the electric motor is electrically isolated from the pump, and the pump is configured to use the transmitted mechanical power to pump fluid.

Description

[0001] Priority / cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 847,389, filed on May 14, 2019, entitled “Method and Apparatus for Mechanically Coupling a Motor to an Electrically Isolated Pump,” the entire contents of which are expressly incorporated herein by reference. Technical Field

[0003] The present disclosure relates to an electric motor that provides mechanical power to an electrically isolated pump configured to pump a fluid for use in a welding system. Background Art

[0004] The limitations and disadvantages of conventional pumps for cooling welding systems will become apparent to those skilled in the art by comparing the conventional pumps to aspects of the methods and systems of the present invention as described in the remainder of this disclosure with reference to the accompanying figures. Summary of the invention

[0005] There are provided methods and systems for methods and apparatus for causing an electric motor to provide mechanical force to a pump electrically isolated from the electric motor, substantially as illustrated in and described in conjunction with at least one of the accompanying drawings, as more fully set forth in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] These and / or other aspects will become apparent and more readily understood from the following description of some example embodiments taken in conjunction with the accompanying drawings.

[0007] Figure 1A is a high-level block diagram of an example of a power conversion circuit, a motor, a pump, and a welding torch according to an embodiment of the present disclosure.

[0008] Figure 1B is a lower level block diagram of an example of a motor power conversion circuit, a motor, and a pump according to an embodiment of the present disclosure.

[0009] Figure 2A is an exploded view of an example coupling system between an electric motor and a fluid pump according to an embodiment of the present disclosure, wherein the electric motor and the pump are electrically isolated and mechanically coupled.

[0010] Figure 2B is a diagram of an example of an electric motor electrically isolated and mechanically coupled to a fluid pump according to an embodiment of the present disclosure.

[0011] The drawings are not necessarily drawn to scale. Where appropriate, similar or identical reference numbers are used to indicate similar or identical parts. DETAILED DESCRIPTION

[0012] Some welding systems (e.g., higher current TIG machines) may offer the option of a water-cooled TIG torch. In these systems, coolant is pumped into the torch assembly including the cable and torch body. The welding power supply may provide appropriate electrical power to the motor to operate the coolant pump. The motor / pump used by the TIG cooler may be an off-the-shelf or readily available product that may also be used in other devices besides welding-type systems, for example. Therefore, these motors may only accept 120V / 240V single-phase AC input voltage.

[0013] Therefore, it is advantageous to use these motors rather than special ordering other motors, because developing a custom motor may require a long lead time, and the cost of a custom motor may be much more expensive than off-the-shelf motors used in a variety of fields. However, the motor may need to be electrically isolated from the pump. The present disclosure provides a description of a mechanical coupling system that electrically isolates the motor from the pump.

[0014] Although power and force have different definitions, because power and force are related, for simplicity, the term "power" can also be used to refer to force.

[0015] Figure 1A is a high-level block diagram of an example of a power conversion circuit, a motor, a pump, and a welding torch according to an embodiment of the present disclosure. Figure 1A , shows a portion of a welding system 100, wherein the welding system 100 includes a welding-type power conversion circuit 110, a motor power conversion circuit 115, a motor 120, a pump 130, and a welding torch 140. The power conversion circuits 110 and 115 receive input power from a power source that can provide, for example, 120VAC, 240VAC, 480VAC, etc. The output power of the welding-type power conversion circuit 110 can be provided to, for example, the welding torch 140. The output power of the motor power conversion circuit 115 can be provided to, for example, the motor 120. For example, the output power of the motor power conversion circuit 115 can include one or both of 120VAC or 240VAC, wherein the appropriate output voltage is provided to the motor 120. The output power of the welding-type power conversion circuit 110 can be referred to as welding-type power. The motor 120 can use the power from the motor power conversion circuit 115 to generate a mechanical force (torque) that can be provided to the pump 130, while electrically isolating the pump 130 from the output power of the motor power conversion circuit 115. The pump 130 may then use mechanical force to pump fluid through the pump 130 to cool, for example, the welding torch 140 .

[0016] Figure 1Bis a lower level block diagram of an example of a motor power conversion circuit, a motor, and a pump according to an embodiment of the present disclosure. Figure 1B , showing the motor power conversion circuit 115, the motor 120 and the pump 130 in more detail.

[0017] The motor power conversion circuit 115 may include, for example, a fuse F1 for protecting an input line, an autotransformer 112 for converting an input voltage of the input power into an output voltage of the output power of the motor power conversion circuit 115, and a connection mechanism 114 for transmitting the output power from the autotransformer 112 to the motor 120. The connection mechanism 114 may also be referred to as a switch module.

[0018] While various autotransformers may have different numbers of nodes, the example autotransformer 112 includes three nodes. Nodes N1 and N3 may be used for input power. Nodes N1 and N3 may also be used when the motor voltage is the same as the input voltage. Nodes N1 and N2 may be used when the motor voltage is half the input voltage. Thus, it can be seen that different needs for output power may use an autotransformer with a different number of nodes, where each node may tap the autotransformer at a different location.

[0019] The motor 120 may also have a fan 122 for cooling the motor 120 and a radiator 132. The pump 130 may be used with the radiator 132, wherein an input port 134 receives a hot fluid from, for example, a TIG welding torch (torch 140 in FIG. 1 ), which is cooled by the fluid pumped by the pump 130. The fluid may be, for example, water. The hot fluid (e.g., hot water) is cooled by the radiator 132, and the cooled fluid (e.g., cooling water) is output via an output port 136.

[0020] Although only three nodes are shown, various embodiments of the present disclosure may show additional circuits for different power outputs where appropriate. For example, there may be additional circuits for various output powers of different voltages for lamps, etc.

[0021] Thus, the motor power conversion circuit 115 may receive input power (line power) via the electrical conductor 111, and output power may be output via electrical nodes N1 and N2 or N1 and N3, where other nodes may be present for different purposes. For example, when the work device 100 is a welding power source, one set of electrical nodes may be used for the pump 120, and another set of nodes may provide power for various appropriate devices (e.g., lights provided to users of the work device 100).

[0022] When the motor voltage is the same as the input voltage, nodes N1 and N3 may provide the input voltage as the motor voltage to the motor 120. If the motor voltage does not need to be changed, then in some embodiments, the input voltage may be provided to the motor 120 without the autotransformer 112. When the autotransformer 112 is not used, the connection mechanism 114 may also not be used.

[0023] Thus, the motor power conversion circuit 115 may receive AC power and output AC power at different voltages, and / or output DC power at one or more voltages.The specific circuitry used in the power conversion circuit 110 may be design dependent.

[0024] Figure 2A is an exploded view of an example coupling system between an electric motor and a fluid pump according to an embodiment of the present disclosure, wherein the electric motor and the pump are electrically isolated and mechanically coupled. Figure 2A An instance of the join system can be used to join Figure 1A The motor and pump in Figure 2A , showing the motor 220 and the pump 230. Also shown are an isolating coupling 240, an isolating ring 242 and an isolating clamp 244, wherein these parts are made of electrically insulating materials. Bolts 245 can be used to tighten the isolating clamp 244.

[0025] The isolation connector 240 is used to transfer the mechanical force (torque) generated by the motor 220 to the pump 230. The isolation connector 240 provides creepage distance and clearance between the motor 220 and the pump 230, and may include, for example, a flange 241 to increase the creepage distance compared to an isolation connector 240 without the flange 241. Creepage distance and clearance are also referred to as electrical spacing "above the surface" and "through the air". Creepage distances and clearances for various voltages may be specified by various standards depending on the jurisdiction.

[0026] The isolation ring 242 provides creepage distance and clearance between the motor 220 and the pump 230. Figure 2A As shown, in some embodiments, the isolation coupler 240 is assembled through the isolation ring 242.

[0027] The isolation clamp 244 is used to tightly couple the motor 220 and the pump 230 together to reduce the rotation of the pump housing relative to the motor housing so that the pump 230 does not move when mechanical force is applied to the pump 230. The isolation clamp 244 also provides clearance and creepage distance between the motor 220 and the pump 230.

[0028] For a given motor voltage used by the motor 220, each of the isolating coupler 240, isolating ring 242, and isolating clamp 244 can contribute to at least a threshold amount of creepage distance and / or clearance required between the motor 220 and the pump 230. The threshold amount of creepage distance and / or clearance can be determined, for example, based on the standards of the appropriate jurisdiction. The creepage distance and / or clearance of each of the isolating coupler 240, isolating ring 242, and isolating clamp 244 can be, for example, a threshold amount of creepage distance and / or electrical clearance.

[0029] Some embodiments of the present disclosure may combine the isolation clip 244 and the isolation ring 242 as one part. Therefore, the clearance and / or creepage distance may be increased compared to a case where the isolation clip 244 is not combined with the isolation ring 242.

[0030] Figure 2B is a diagram of an example of an electric motor electrically isolated and mechanically coupled to a fluid pump according to an embodiment of the present disclosure. Figure 2B The motor 220 and pump 230 are shown coupled together using an isolation coupler 240, an isolation ring 242, and an isolation clamp 244. Thus, the pump 230 may be isolated from the motor voltage used by the motor 220 to generate mechanical power provided to the pump 230.

[0031] Thus, it can be seen that the present disclosure provides an electrically isolated pump system, including: a welding-type power conversion circuit configured to convert input power into welding-type power; a motor configured to output mechanical power using a motor voltage derived from the input power by the motor power conversion circuit; and an electrically insulating isolation connector configured to transmit the mechanical power to the pump. The isolation connector includes a flange so that the flange provides an increased creepage distance compared to an isolation connector that does not include a flange.

[0032] The motor may be electrically isolated from the pump, and the pump is configured to use the transmitted mechanical power to pump the fluid. The pump system includes an electrically insulating isolating ring configured to mechanically couple the motor to the pump and electrically isolate the motor from the pump, wherein the isolating connector is configured to pass through the isolating ring. The isolating ring may be configured to provide at least a threshold clearance and a threshold creepage distance. Some embodiments may cause the isolating clamp to include the isolating ring.

[0033] The pump system may include an electrically insulating spacer clamp configured to secure the motor to the pump. The spacer clamp may provide at least a threshold clearance and a threshold creepage distance. The motor may use a motor voltage of, for example, 240VAC.

[0034] The motor power conversion circuit may be, for example, an autotransformer, wherein an output voltage of the power conversion circuit may be transmitted to the motor as a motor voltage. When the input voltage of the input power is greater than the motor voltage, the switch module may be configured to be connected to an output terminal of the motor power conversion circuit that substantially outputs the motor voltage. When the input voltage of the input power is substantially the motor voltage, the switch module may be configured to be connected to an output terminal of the motor power conversion circuit that substantially outputs the input voltage. When the input voltage of the input power is substantially equal to the motor voltage, the motor may be connected to the input voltage without using the motor power conversion circuit.

[0035] The present disclosure may also provide a connection system between a motor and a fluid pump, comprising: an electrically insulating isolation connector configured to transmit mechanical power output by the motor to the fluid pump; and an electrically insulating isolation clamp configured to securely connect the motor to the fluid pump. The connection system may include an electrically insulating isolation ring configured to electrically isolate the motor from the pump, wherein the isolation connector is configured to pass through the isolation ring.

[0036] The isolating ring may be configured to provide at least a threshold clearance and a threshold creepage distance. The isolating clamp may include an electrically insulating isolating ring configured to electrically isolate the motor from the pump. The isolating clamp may also be configured to provide at least a threshold clearance and a threshold creepage distance. The isolating clamp may include a flange such that the flange provides an increased creepage distance compared to an isolating coupler that does not include a flange.

[0037] The present disclosure may also provide an electrically isolated pump system, comprising: an electric motor configured to use an input voltage of input power to output mechanical power; and an electrically insulating coupling system. The coupling system may include: an electrically insulating isolation coupling configured to transmit mechanical power to a pump; an electrically insulating isolation ring configured to electrically isolate the electric motor from the pump, wherein the isolation coupling is configured to pass through the isolation ring; and an electrically insulating isolation clamp configured to fix the electric motor to the pump. The electric motor may be electrically isolated from the pump, for example, and the pump is configured to use the transmitted mechanical power to pump a fluid.

[0038] As used herein, a welding-type power supply refers to any device capable of using input power to power welding, cladding, plasma cutting, induction heating, laser processing (including laser welding, laser hybrid welding and laser cladding), carbon arc cutting, gouging, resistance preheating and / or control circuits, as well as control circuits and auxiliary circuits associated therewith, wherein the device may be (but not limited to) an autotransformer, a transformer, a transformer-rectifier, an inverter, a converter, a resonant power supply, a quasi-resonant power supply, a switch-mode power supply, etc.

[0039] Some disclosed examples may describe current being conducted "from" and / or conducted "to" some locations in a circuit and / or power supply. Similarly, some disclosed examples describe current being "provided" via one or more paths, which may include one or more conductive or partially conductive elements. The terms "from," "to," and "provided" used to describe the conduction of current do not necessarily specify the direction or polarity of the current. Rather, for a given circuit, these currents may be conducted in either direction, or have either polarity, even if example current polarities or directions are provided or shown.

[0040] For convenience, the term "electricity" is used in this specification, but "electricity" also includes related metrics such as energy, force, current, voltage, and enthalpy. For example, controlling "electricity" may include controlling voltage, current, energy, and / or enthalpy, and / or controlling based on "electricity" may include controlling based on voltage, current, energy, and / or enthalpy. Electrical power measured in watts as the product of voltage and current (e.g., V*I power) may be referred to herein as "wattage".

[0041] As used herein, "and / or" means any one or more of the items in the list joined by "and / or". As an example, "x and / or y" means any one of 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" means any one of 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 serving as a non-limiting example, instance, or illustration. As used herein, the term "for example" cites a list of one or more non-limiting examples, examples, or illustrations. As used herein, a circuit is “operable” to perform a function so long as the circuit includes the necessary hardware and code (if necessary) to perform the function, regardless of whether performance of the function is disabled or not enabled (e.g., by user-configurable settings, factory trims, etc.).

[0042] Although the method and / or system of the present invention has been described with reference to certain embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the method and / or system of the present invention. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the present disclosure without departing from the scope of the present disclosure. Therefore, the method and / or system of the present invention is not limited to the specific embodiments disclosed. In fact, the method and / or system of the present invention will include all embodiments that fall within the scope of the appended claims, both literally and according to the doctrine of equivalents.

Claims

1. An electrically isolated pump system, comprising: a welding-type power conversion circuit configured to convert input power into welding-type power; an electric motor (120, 220) configured to output mechanical power using a motor voltage derived from the input power by a motor power conversion circuit (115); as well as an isolating coupling (240) configured to transmit the mechanical power generated by the motor (120, 220) to a pump (130, 230), wherein the isolating coupling (240) is an electrically insulating material, a spacer clip (244) configured to secure the motor (120, 220) to the pump (130, 230) by clamping around a first periphery of a first portion of the pump (130, 230) and a second periphery of a second portion of the motor (120, 220), wherein the spacer clip (244) is an electrically insulating material, The motor (120, 220) is electrically isolated from the pump (130, 230), and the pump (130, 230) is configured to pump fluid using the transmitted mechanical power.

2. The system of claim 1, comprising an isolating ring (242), the isolating ring (242) being configured to: mechanically couple the motor (120, 220) to the pump (130, 230) and electrically insulate the motor (120, 220) from the pump (130, 230), wherein the isolating ring (242) is an electrically insulating material, wherein the isolating connector (240) is configured to pass through the isolating ring (242).

3. The system of claim 2, wherein the isolation ring (242) is configured to provide at least a threshold clearance and a threshold creepage distance.

4. The system of claim 1, wherein the isolation clamp (244) comprises an isolation ring (242).

5. The system of claim 1, wherein the isolation clip (244) is configured to provide at least a threshold clearance and a threshold creepage distance.

6. The system of claim 1, wherein the electric motor (120, 220) uses a motor voltage of substantially 240 volts AC.

7. The system of claim 1, wherein the motor power conversion circuit (115) is an autotransformer (112).

8. The system of claim 1, comprising a switching module for transmitting the motor voltage from the motor power conversion circuit (115) to the motor (120, 220).

9. The system according to claim 8, wherein when the input voltage of the input power is greater than the motor voltage, the switch module is configured to be connected to an output terminal of the motor power conversion circuit (115) that substantially outputs the motor voltage.

10. The system of claim 8, wherein when the input voltage of the input power is substantially the motor voltage, the switch module is configured to be connected to an output terminal of the motor power conversion circuit (115) that substantially outputs the input voltage.

11. The system of claim 1, wherein when an input voltage of the input power is substantially equal to the motor voltage, the motor (120, 220) is connected to the input voltage without using the motor power conversion circuit (115).

12. The system of claim 1, wherein the isolating coupling (240) includes a flange (241) such that the flange (241) provides an increased creepage distance compared to the isolating coupling (240) not including the flange (241).

13. A connection system between an electric motor (120, 220) and a fluid pump (130, 230), comprising: an electrically insulating isolating coupling (240) configured to transmit mechanical power output by the motor (120, 220) to the fluid pump (130, 230); as well as An electrically insulating spacer clamp (244) is configured to secure the motor (120, 220) to the fluid pump (130, 230) by clamping around a first periphery of a first portion of the fluid pump (130, 230) and a second periphery of a second portion of the motor (120, 220).

14. The system of claim 13, comprising an electrically insulating isolating ring (242) configured to electrically isolate the motor (120, 220) from the pump (130, 230), wherein the isolating connector (240) is configured to pass through the isolating ring (242).

15. The system of claim 14, wherein the isolation ring (242) is configured to provide at least a threshold clearance and a threshold creepage distance.

16. The system of claim 13, wherein the isolation clamp (244) comprises an electrically insulating isolation ring (242) configured to electrically isolate the motor (120, 220) from the pump (130, 230).

17. The system of claim 13, wherein the isolation clip (244) is configured to provide at least a threshold clearance and a threshold creepage distance.

18. The system of claim 13, wherein the isolating coupling (240) includes a flange (241) such that the flange (241) provides an increased creepage distance compared to the isolating coupling (240) not including the flange (241).

19. An electrically isolated pump system comprising: an electric motor (120, 220) configured to output mechanical power using an input voltage of input power; as well as An electrically insulating connection system, the electrically insulating connection system comprising: an electrically insulating isolating coupling (240) configured to transmit the mechanical power to a pump (130, 230); an electrically insulating isolating ring (242) configured to electrically isolate the motor (120, 220) from the pump (130, 230), wherein the isolating coupling (240) is configured to pass through the isolating ring (242); and an electrically insulating spacer clip (244) configured to secure the motor (120, 220) to the pump (130, 230) by clamping around a first periphery of a first portion of the pump (130, 230) and a second periphery of a second portion of the motor (120, 220), The motor (120, 220) is electrically isolated from the pump (130, 230), and the pump (130, 230) is configured to pump fluid using the transmitted mechanical power.

20. An electrically isolated pump system for a welding system configured to perform a welding operation, comprising: a welding-type power supply configured to convert input power into power for use during the welding operation; a motor configured to output mechanical power using a motor voltage derived from the input power via a motor power conversion circuit; and an electrically insulating isolating coupling configured to transmit the mechanical power from the motor to a pump and to electrically isolate the pump from the motor, an electrically insulating spacer clip configured to secure the motor to the pump by clamping around a first periphery of the first portion of the pump and a second periphery of the second portion of the motor, wherein the electrically insulating isolating connector is a mechanical connector made of an electrically insulating material, and the electrically insulating isolating connector defines a first end and a second end; The electrically insulating isolating connector is configured to be mechanically connected to the motor through the first end and to be mechanically connected to the pump through the second end so as to transmit torque from the motor to the pump.

21. A connection system between an electric motor and a fluid pump, comprising: an electrically insulating isolating coupling configured to transmit mechanical power output by the electric motor to the fluid pump; wherein the electrically insulating isolating connector is a mechanical connector made of an electrically insulating material, the electrically insulating isolating connector defining a first end and a second end; and wherein the electrically insulating isolating connector is configured to be mechanically connected to the motor through the first end and to be mechanically connected to the fluid pump through the second end so as to transfer torque from the motor to the fluid pump; and An electrically insulating spacer clamp is configured to secure the motor to the fluid pump by clamping around a first periphery of a first portion of the fluid pump and a second periphery of a second portion of the motor.

22. An electrically isolated pump system comprising: an electric motor configured to output mechanical power using an input voltage of the input electric power; as well as An electrically insulating connection system, the electrically insulating connection system comprising: an electrically insulating isolating coupling configured to transmit the mechanical power from the motor to a pump; wherein the electrically insulating isolating connector is a mechanical connector made of electrically insulating material as a single component, the electrically insulating isolating connector defining a first end and a second end; and wherein the electrically insulating isolating coupling is configured to be mechanically connected to the motor through the first end and to be mechanically connected to the pump through the second end to transfer torque from the motor to the pump; an electrically insulating isolating ring configured to electrically isolate the motor from the pump, wherein the electrically insulating isolating coupling is configured to pass through the electrically insulating isolating ring; and an electrically insulating spacer clip configured to secure the motor to the pump by clamping around a first periphery of the first portion of the pump and a second periphery of the second portion of the motor, wherein the motor is electrically isolated from the pump, and the pump is configured to pump a fluid using the transmitted mechanical power.

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