Battery-powered welding machine

Abstract

We provide battery-powered welding machines. [Solution] The battery-powered welding machine includes a battery, a charging circuit configuration operably connected to the battery, and an output circuit configuration that receives electrical energy from the battery to generate a welding arc. The output circuit configuration includes a bleed circuit for selectively releasing residual energy in the output circuit configuration. An isolation switch is connected between the battery and the output circuit configuration to selectively connect and disconnect the battery from the output circuit configuration. A control system is operably connected to the isolation switch to control the operation of the isolation switch and is operably connected to the bleed circuit to control the release of residual energy in the output circuit configuration. The control system detects a high voltage state in the output circuit configuration, and when a high voltage state is detected, it automatically operates the isolation switch to disconnect the battery from the output circuit configuration and automatically activates the bleed circuit to release residual energy.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 706,818, filed Oct. 14, 2024, the disclosure of which is incorporated herein by reference, and U.S. Non - Provisional Patent Application No. 19 / 297,084, filed Aug. 12, 2025, the disclosure of which is incorporated herein by reference.

Background Art

[0002] The present invention relates to welding machines, and particularly to battery - type welding machines and the control of charging and discharging of the battery or battery pack of a welding machine. Due to a failure in a battery - type welding machine, the battery voltage level may become full and / or an abnormal high current level may exist in the output of the welding machine, which may be undesirable. Further, welding operations can generate undesirable voltage fluctuations in a battery charging circuit configuration. Therefore, an improvement in battery - type welding machines to address one or more of such deficiencies would be beneficial.

Summary of the Invention

Means for Solving the Problems

[0003] The following summary presents a simplified summary in order to provide a basic understanding of some aspects of the devices, systems, and / or methods described herein. This summary is not an extensive overview of the devices, systems, and / or methods described herein. This summary is not intended to identify key elements of such devices, systems, and / or methods or to accurately depict their scope. Its sole purpose is to present some concepts in a simplified form as an introduction to a more detailed description that will be presented later.

[0004] A battery-powered welding machine is provided according to one aspect of the present invention. The battery-powered welding machine includes a battery, a charging circuit configuration operably connected to the battery for charging the battery, and an output circuit configuration operably connected to the battery for receiving electrical energy from the battery to generate a welding arc. The output circuit configuration includes a bleed circuit for selectively releasing residual energy in the output circuit configuration. An isolation switch is connected between the battery and the output circuit configuration to selectively connect and disconnect the battery from the output circuit configuration. A control system is operably connected to the isolation switch to control the operation of the isolation switch and operably connected to the bleed circuit to control the release of residual energy in the output circuit configuration. The control system is configured to detect high-voltage conditions in the output circuit configuration, and when a high-voltage condition is detected, to automatically operate the isolation switch to disconnect the battery from the output circuit configuration and to automatically activate the bleed circuit to release residual energy in the output circuit configuration.

[0005] A battery-powered welding machine is provided according to another aspect of the present invention. The battery-powered welding machine includes a battery, a charging circuit configuration operably connected to the battery for charging the battery, and an output circuit configuration operably connected to the battery for receiving electrical energy from the battery to generate a welding arc. The output circuit configuration includes a bleed circuit for selectively releasing residual energy in the output circuit configuration. A current sensor generates a welding current level signal. An isolation switch is connected between the battery and the charging circuit configuration for selectively connecting and disconnecting the battery from the charging circuit configuration. A controller is operably connected to the isolation switch to control the operation of the isolation switch. The controller is configured to automatically operate the isolation switch to disconnect the battery from the charging circuit configuration during welding.

[0006] A battery-powered welding machine is provided according to another aspect of the present invention. The battery-powered welding machine includes a battery, a charging circuit configuration operably connected to the battery for charging the battery, and an output circuit configuration operably connected to the battery for receiving electrical energy from the battery to generate a welding arc. A first isolation switch is connected between the battery and the output circuit configuration to selectively connect and disconnect the battery from the output circuit configuration. A second isolation switch is connected between the battery and the charging circuit configuration to selectively connect and disconnect the battery from the charging circuit configuration. A controller is operably connected to the first isolation switch to control the operation of the first isolation switch, and is operably connected to the second isolation switch to control the operation of the second isolation switch. The controller is configured to automatically operate the second isolation switch to disconnect the battery from the charging circuit configuration during welding. The controller is further configured to detect a high-voltage condition in the output circuit configuration, and when a high-voltage condition is detected, to automatically operate the first isolation switch to disconnect the battery from the output circuit configuration.

[0007] Those skilled in the art in the field to which the present invention relates will be able to understand the above-described and other embodiments of the present invention by referring to the following accompanying drawings while reading the description below. [Brief explanation of the drawing]

[0008] [Figure 1] This shows a battery-powered welding machine.

[0009] [Figure 2] A schematic circuit diagram of a battery-powered welding machine is shown. [Modes for carrying out the invention]

[0010] The present invention relates to a battery-powered welding machine. The present invention will be described here with reference to the drawings. Throughout the drawings, similar reference numerals are used to indicate similar elements. It should be noted that the various drawings, both individually and within a given drawing, are not necessarily drawn to scale, and in particular, the size of components is depicted at arbitrary sizes for the sake of clarity. The following description includes numerous specific details for illustrative purposes to ensure a full understanding of the invention. However, it is evident that the invention can be practiced without these specific details. In addition, other embodiments of the invention are possible, and the invention can be practiced and carried out in ways other than those described. The terms and expressions used in describing the present invention are for the purpose of facilitating understanding of the invention and should not be construed as limiting.

[0011] As used herein, “at least one,” “one or more,” and “and / or” are non-restrictive expressions that are both conjunctive and disjunctive in function. For example, each of the expressions “at least one of A, B, and C,” “at least one of A, B or C,” “one or more of A, B, and C,” “one or more of A, B or C,” and “A, B and / or C” means A only, B only, C only, A and B together, A and C together, B and C together, or A and, B and, C together. Any disjunctive phrase representing two or more alternative terms in the description of embodiments, claims, or drawings should be understood as presuming the possibility of including one of those terms, either one of those terms, or both of those terms. For example, the phrase “A or B” should be understood as including the possibility of “A” or “B” or “A and B.”

[0012] The embodiments of the present invention described herein are described in relation to shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW), but other embodiments of the present invention are not limited thereto. For example, embodiments of the present invention may be used in gas metal arc welding (GMAW) systems, cored arc welding (FCAW) systems and / or metal cored arc welding (MCAW) systems. Embodiments of the present invention may also be used in metal welding operations similar to welding, such as hard build-up and cladding. As used herein, the term “welding” is intended to encompass all these techniques, as all of these techniques involve material welding that either joins or constructs workpieces. Therefore, for efficiency, the term “welding” will be used below in the description of exemplary embodiments, but it is intended to include all of these material welding operations, whether or not multiple workpieces are joined. Embodiments of the present invention may also be used in plasma cutting operations or systems.

[0013] Figure 1 shows an exemplary battery-powered welding machine 100. The welding machine 100 includes a workpiece clamp 102 for connecting to a workpiece or welding table and an electrode holder 104. The welding machine 100 in Figure 1 is configured for SMAW welding, but can also be configured for GTAW or other welding operations by changing the welding torch and selecting the appropriate welding process and parameters via the welding machine's user interface.

[0014] Figure 2 is a schematic diagram of the power circuit configuration of an exemplary battery-powered welding machine. The load in Figure 2 is located at the output of the welding circuit and is primarily the electric arc 106 generated during welding, between the torch 110 (e.g., an electrode holder or "stinger" that holds a welding rod, GTAW torch, GMAW torch, etc.) and the workpiece 112. As is known in the art, the chopper circuit configuration 108 controls the welding output voltage and / or current for the welding operation. Power for the welding operation is supplied by a battery 114 or battery pack. The battery 114 or battery pack (hereinafter referred to as "battery") may include multiple batteries connected together. In certain embodiments, the battery 114 is integrated with the welding machine and is not intended to be removed for recharging, and the welding machine itself includes a charging circuit configuration 116 and a battery management system that controls the charging of the battery. The charging circuit configuration 116 is operably connected to the battery 114 to charge the battery. In one exemplary embodiment, the charging circuit configuration 116, as shown, includes, among other things, an inverter (e.g., an H-bridge inverter), a transformer, and a rectifier, which can supply an appropriate DC voltage level to charge the battery 114. The charging circuit configuration 116 shown in Figure 2 is an example of a charging circuit configuration that can be used in a welding machine, and those skilled in the art will recognize that other charging circuits or circuit configurations may be used.

[0015] The voltage level of battery 114 can be significantly higher than the desired welding voltage level. For example, the welding voltage level supplied to the torch 110 may be in the range of 20-30V. However, the voltage level of battery 114 supplying the chopper circuit configuration 108 can be more than twice the welding voltage level, such as over 60V or over 90V. In one exemplary embodiment, battery 114 powers the chopper circuit configuration 108 at approximately 96VDC. The chopper 108 is operably connected to battery 114 and is part of an output circuit configuration that receives electrical energy from the battery to generate a welding arc 106. The chopper 108 is powered by battery 114 and reduces the battery voltage level to a level suitable for welding work.

[0016] Battery 114 can be selectively connected to and isolated from chopper circuit configuration 108 by a first controllable isolation switch 117, such as a transistor switch. The isolation switch 117 is connected between battery 114 and output chopper circuit configuration 108 to selectively connect and disconnect the battery from the output circuit configuration. In Figure 2, the isolation switch 117 is located along the negative return path to battery 114, but may also be located along the positive output of the battery if necessary. Battery 114 can also be selectively connected to and disconnected from charging circuit configuration 116 by a second controllable isolation switch 118. The second isolation switch 118 is connected between battery 114 and charging circuit configuration 116 to selectively connect and disconnect the battery from the charging circuit configuration. In Figure 2, the second isolation switch 118 is located along the positive power path to battery 114, but may also be located along the negative return path to charging circuit configuration 116 if necessary. As described herein, the operation of the isolation switches 117, 118 may be controlled by the controller 120 or a control system.

[0017] The controller 120 may be an electronic controller and may include one or more processors. For example, the controller 120 may include one or more microprocessors, microcontrollers, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), discrete logic circuit configurations, etc. The controller 120 may further include memory that can store program instructions causing the controller to provide functionality deemed to belong to this specification. The memory may include one or more volatile media, non-volatile media, magnetic media, optical media, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically erasable programmable ROM (EEPROM), flash memory, etc. The controller 120 may further include one or more analog-to-digital (A / D) converters for processing various analog inputs to the controller.

[0018] To recharge the battery 114, the welding machine may be connected to a power source of AC power 122, such as a commercial power supply or the output of a generator. In Figure 2, the power source of AC power 122 is shown as 110V, but it should be noted that the power source of AC power may also have other appropriate voltage levels, such as 208V, 220V, etc. In certain embodiments, the welding machine may include a pre-charge circuit configuration 140 that can reduce high inrush current, reduce electrical stress, protect components, and prevent spark generation when connected to the power source of AC power 122. In the exemplary embodiment of Figure 2, the pre-charge circuit configuration 140 includes a controllable switch connected in parallel with a resistor. The welding machine may include a rectifier 124 that supplies DC power to a charging circuit configuration 116. In the exemplary embodiment of Figure 2, the charging circuit configuration 116 includes an inverter, such as an H-bridge inverter, that supplies power to a transformer and an additional rectifier that supplies DC power at an appropriate voltage / current level to charge the battery 114 when the welding machine is connected to the power source of AC power 122.

[0019] Welding power is supplied to the torch 110 by the battery 114, regardless of whether the welding machine is connected to the AC power supply 122. The battery 114 can be selectively connected to and isolated from the chopper circuit configuration 108 and the charging circuit configuration 116 by the first isolation switch 117 and the second isolation switch 118, and their operation is controlled by the controller 120. It is common for the chopper 108 to supply an open-circuit voltage (OCV) at the welding machine output between the torch 110 and the workpiece 112 or between the welding machine output connections, even when welding is not occurring. For example, when the welding machine is turned on and ready to begin welding, an OCV will be present at the welding machine output. An exemplary normal OCV range is 20-30VDC.

[0020] A fault may occur that could cause the OCV between the torch 110 and the workpiece 112 (or between the output connections of the welding machine) to be higher than the normal OCV range supplied by the chopper 108. For example, if the transistor switch 126 in the chopper 108 shorts and closes, the OCV will be at the voltage level of the battery 114. The fault can also cause abnormally high currents (e.g., over 200A, 250A, 300A, etc.) to flow through the torch 110. Certain regulatory authorities require that when the battery 114 supplies a voltage level higher than a threshold level (e.g., 60VDC), the no-load OCV (i.e., when no active welding is occurring) must be below another threshold level (e.g., 60VDC). The controller 120 is configured to monitor the OCV via a voltage sensor 128 that measures the output voltage of the welding machine. If the OCV is abnormally high (e.g., above 60VDC) and no welding is occurring, the controller 120 can determine this condition from the voltage level signal supplied by the voltage sensor 128. The controller 120 is operably connected to the isolation switch 117 to control the operation of the isolation switch. The controller 120 is configured to detect a high voltage condition in the output chopper circuit configuration 108 by comparing the measured OCV with a threshold voltage level, and when a high voltage condition is detected, it automatically operates the isolation switch 117 to disconnect the battery 114 from the output circuit configuration. The controller 120 can generate a fault signal or fault condition whenever the chopper 108 is not functioning properly. In response to a high OCV fault condition, the controller 120 can automatically disconnect the battery 114 from the chopper 108 by opening the isolation switch 117. In certain embodiments, if active welding is occurring, the controller 120 does not generate a fault signal in response to high OCV.

[0021] The welding machine may include a current sensor 134 (e.g., a current transformer, shunt, etc.) for measuring the flow of welding current between the battery 114 and the chopper 108 or the flow of current to the torch 110. The current sensor 134 is operably connected to a controller 120, which supplies a welding current level signal to the controller. As described above, a fault in the chopper 108 can cause an abnormally high current to flow through the torch 110. The controller 120 is configured to monitor the welding current level. If the welding current is abnormally high (e.g., above 200A, 250A, 300A, etc., above a threshold level), the controller 120 can determine this condition from the welding current level signal supplied by the current sensor 134. The controller 120 is configured to detect a high current condition in the output chopper circuit configuration 108 by comparing the measured current level to a threshold current level, and when a high current condition is detected, it is configured to automatically operate an isolation switch 117 to disconnect the battery 114 from the output circuit configuration.

[0022] In addition to automatically isolating the chopper 108 from the battery 114 by opening the isolation switch 117, the controller 120 can also automatically discharge the capacitor 130 of the chopper 108 in response to a high OCV fault condition or a high current fault condition, or release residual energy in the welding machine's output circuit configuration in response to other supply-related problems or faults. The output circuit configuration may include, for example, a bleed circuit 132 having a resistor and a transistor switch, which releases energy from the capacitor 130 through the resistor when a high voltage condition, a high current condition or other fault is detected in the output circuit configuration. Figure 2 schematically shows the bleed circuit 132 in the chopper 108. The bleed circuit 132 selectively releases residual energy (e.g., energy stored in the capacitor 130) in the welding machine's output circuit configuration under the control of the controller 120. The controller 120 is operably connected to the transistor switch of the bleed circuit 132 to control the release of residual energy in the output circuit configuration 108. When controller 120 detects a high OCV fault, a high current fault, or other fault condition, it can automatically disconnect chopper 108 from battery 114 via isolation switch 117 and automatically activate bleed circuit 132 (for example, by turning on the transistor switch in the bleed circuit) to release residual energy from capacitor 130, thereby reducing the OCV to near 0V. The resistor in bleed circuit 132 has a relatively small value, such as 15 ohms, allowing capacitor 130 to discharge quickly, for example, within a few milliseconds. Rapid discharge of capacitor 130 may be desirable when a high current fault occurs due to a short circuit in chopper 108 or the like.

[0023] When active welding occurs, it may be desirable to disconnect the battery 114 from the charging circuit configuration 116 during welding to protect the charging circuit configuration from, for example, voltage fluctuations. For this reason, a second isolation switch 118 is connected between the battery 114 and the charging circuit configuration 116 to selectively connect and disconnect the battery from the charging circuit configuration. A current sensor 134 supplies a welding current level signal to the controller 120, which can determine from the current level whether welding is occurring. If welding is occurring, welding current flows from the battery 114 through the chopper 108 to the torch 110. This flow of welding current is sensed by the current sensor 134. Based on the welding current level signal from the current sensor 134, the controller 120 is configured to automatically activate the second isolation switch 118, opening the switch and disconnecting the battery 114 from the charging circuit configuration 116 during welding. Thus, in certain embodiments, battery charging is linked to the absence of active welding. When the welding machine is connected to the power supply 122 and no welding is occurring, the controller 120 keeps the second isolation switch 118 closed and charges the battery 114. When the welding machine is connected to the power supply 122 and welding is occurring as indicated by the current level signal from the current sensor 134, the controller 120 opens the second isolation switch 118 to protect the charging circuit configuration 116 (for example, from large voltage fluctuations).

[0024] In certain embodiments, the welding machine may include a plurality of controllers. FIG. 2 shows two controllers 120, 136. The above-mentioned controller 120 may be regarded as a battery management system controller, while the controller 136 may be regarded as a chopper controller. For example, the chopper controller 136 can control the operation of the transistor switch 126 of the chopper circuit configuration 108. The two controllers 120, 136 are part of the overall control system of the welding machine. The two controllers 120, 136 can communicate bidirectionally, for example, via a CAN bus (Controller Area Network bus), to exchange information such as operating status, fault status, operating parameters, etc. The chopper controller 136 can receive a voltage level signal from the voltage sensor 128 and transmit voltage level information to the battery management system controller 120, whereby the battery management system controller can monitor the OCV of the welding machine. The chopper controller 136 can also notify the battery management system controller 120 when an active welding is occurring, whereby the battery management system controller can disconnect the battery 114 from the charging circuit configuration 116. The chopper circuit configuration 108 may include an additional current sensor 137 for measuring the welding current level. The current sensor 137 is operatively connected to the chopper controller 136, and this current sensor supplies a welding current level signal to the chopper controller.

[0025] The chopper circuit configuration 108 may include an additional bleed circuit 138 that is operated by a chopper controller 136. The additional bleed circuit 138 may be controlled in the same manner as the bleed circuit 132 controlled by the battery management system controller 120 described above. In addition, when the welder is turned off, the chopper controller 136 can operate the transistor switch of the bleed circuit 138 to discharge the chopper capacitor 130. It may be desirable to discharge the capacitor 130 at a slower speed when the welder is off than when a high current fault condition is detected. Therefore, the resistor of the additional bleed circuit 138 may be larger than the resistor of the bleed circuit 132. An exemplary value of the resistor of the additional bleed circuit 138 is 2000 ohms (2 kΩ). In a particular embodiment, the additional bleed circuit 138, which has a higher resistance and a slower bleed duration than the bleed circuit 132, is operated when a high OCV fault condition is detected or when the welder is turned off, and the bleed circuit 132 is operated when a high current fault is detected.

[0026] The welder may include precharge circuits 140, 142 to reduce the inrush current. The first precharge circuit 140 has a resistor and a switch in parallel. The resistor prevents a high inrush current and is switched by the parallel switch after a short delay. The second precharge circuit 142 has a switch and an inductor connected in parallel with an isolation switch 117. The isolation switch, when activated, operates (e.g., closes) after a short delay to bypass the precharge circuit 142 and at the same time the switch of the precharge circuit opens to remove the inductor of the precharge circuit from the return path to the battery 114.

[0027] In a particular embodiment, the welder may include an interlock switch that needs to be closed to turn on the welder. The interlock switch can be actuated or closed only when the outer case or housing of the welder is properly installed to protect the operator from contact with the powered components within the welder.

[0028] Naturally, this disclosure is illustrative and can be modified in various ways by adding, modifying, or deleting details without departing from the fair scope of the teachings contained herein. Therefore, the present invention is not limited to the specific details of this disclosure, except to the extent that the following claims are necessarily limited in this way. [Explanation of Symbols]

[0029] 100 Battery-powered welding machine 102 Work Clamp 104 Electrode holder 106 Electric Arc 108 Chopper Circuit Configuration 110 Torch 112 Workpieces 114 batteries 116 Charging circuit configuration 117 First Insulation Switch 118 Second Insulation Switch 120 Battery Management System Controller 122 Electric power supply 124 Rectifier 126 Transistor Switches 128 Voltage Sensor 130 Capacitors 132 Bleed Circuit 134 Current Sensor 136 Chopper Controller 137 Additional current sensors 138 Additional bleed circuit 140 First pre-charge circuit configuration 142 Second pre-charge circuit configuration

Claims

1. A battery-powered welding machine, Battery and A charging circuit configuration which is operably connected to the battery and charges the battery, An output circuit configuration that is operably connected to the battery and receives electrical energy from the battery to generate a welding arc, the output circuit configuration including a bleed circuit for selectively releasing residual energy in the output circuit configuration, An isolation switch is connected between the battery and the output circuit configuration to selectively connect and disconnect the battery from the output circuit configuration, A control system operably connected to the isolation switch to control the operation of the isolation switch, and operably connected to the bleed circuit to control the release of residual energy in the output circuit configuration. A battery-powered welding machine, comprising a control system configured to detect a high-voltage state in the output circuit configuration, and when the high-voltage state is detected, to automatically activate the isolation switch to disconnect the battery from the output circuit configuration, and to automatically activate the bleed circuit to release the residual energy in the output circuit configuration.

2. The battery-powered welding machine according to claim 1, wherein the battery voltage level supplied to the output circuit configuration is greater than 60V.

3. The output circuit configuration includes a chopper, as described in claim 2 of the battery-powered welding machine.

4. The battery-powered welding machine according to claim 2, further comprising a current sensor operably connected to the control system, the current sensor providing the control system with a welding current level signal, and the control system being configured to detect a high current state in the output circuit configuration, and when the high current state is detected, to automatically operate the isolation switch to disconnect the battery from the output circuit configuration.

5. An additional isolation switch connected between the battery and the charging circuit configuration, which selectively connects and disconnects the battery from the charging circuit configuration, A current sensor operably connected to the control system and The battery-powered welding machine according to claim 2, further comprising the current sensor providing a welding current level signal to the control system, and the control system being configured to automatically operate the additional isolation switch to disconnect the battery from the charging circuit configuration during welding.

6. The battery-powered welding machine according to claim 5, wherein the welding operation is covered metal arc welding or gas tungsten arc welding.

7. The battery-powered welding machine according to claim 5, wherein the control system is configured to automatically operate the additional isolation switch based on the welding current level signal to disconnect the battery from the charging circuit configuration.

8. The battery-powered welding machine according to claim 7, wherein the residual energy is stored in a capacitor, and the bleed circuit includes a resistor for discharging the capacitor.

9. A battery-powered welding machine, Battery and A charging circuit configuration which is operably connected to the battery and charges the battery, An output circuit configuration that is operably connected to the battery and receives electrical energy from the battery to generate a welding arc, the output circuit configuration including a bleed circuit for selectively releasing residual energy in the output circuit configuration, A current sensor that generates a welding current level signal, An isolation switch is connected between the battery and the charging circuit configuration to selectively connect and disconnect the battery from the charging circuit configuration, A controller operably connected to the isolation switch and controlling the operation of the isolation switch, configured to automatically operate the isolation switch to disconnect the battery from the charging circuit configuration during welding work. Battery-powered welding machines, including those mentioned.

10. The battery-powered welding machine according to claim 9, wherein the battery voltage level supplied to the output circuit configuration is greater than 60V.

11. The output circuit configuration includes a chopper, as described in claim 10.

12. The battery-powered welding machine according to claim 10, wherein the welding operation is covered metal arc welding or gas tungsten arc welding.

13. The battery-powered welding machine according to claim 10, wherein the controller is configured to automatically operate the isolation switch based on the welding current level signal to disconnect the battery from the charging circuit configuration.

14. The battery-powered welding machine according to claim 13, wherein the residual energy is stored in a capacitor, and the bleed circuit includes a resistor for discharging the capacitor.

15. A battery-powered welding machine, Battery and A charging circuit configuration which is operably connected to the battery and charges the battery, An output circuit configuration which is operably connected to the aforementioned battery and receives electrical energy from the battery to generate a welding arc, A first isolation switch is connected between the battery and the output circuit configuration to selectively connect and disconnect the battery from the output circuit configuration, A second isolation switch is connected between the battery and the charging circuit configuration to selectively connect and disconnect the battery from the charging circuit configuration, A controller operably connected to the first isolation switch to control the operation of the first isolation switch, and operably connected to the second isolation switch to control the operation of the second isolation switch, wherein the controller is configured to automatically operate the second isolation switch to disconnect the battery from the charging circuit configuration during welding work. A battery-powered welding machine, further comprising a controller configured to detect a high-voltage state in the output circuit configuration, and when the high-voltage state is detected, to automatically operate the first isolation switch to disconnect the battery from the output circuit configuration.

16. The battery-powered welding machine according to claim 15, wherein the battery voltage level supplied to the output circuit configuration is greater than 60V.

17. The output circuit configuration includes a chopper, as described in claim 16.

18. The battery-powered welding machine according to claim 16, wherein the welding operation is covered metal arc welding or gas tungsten arc welding.

19. The battery-powered welding machine according to claim 16, further comprising a current sensor operably connected to the controller, the current sensor providing the controller with a welding current level signal, and the controller being configured to automatically operate the second isolation switch based on the welding current level signal to disconnect the battery from the charging circuit configuration.

20. The battery-powered welding machine according to claim 19, wherein the controller is further configured to detect a high current state in the output circuit configuration, and when the high current state is detected, to automatically operate the first isolation switch to disconnect the battery from the output circuit configuration.

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