Hysteretic Boost Voltage Control for Low-Noise Welding Idle States
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Solution Overview
Problem
Conventional welding systems face challenges with electrical noise from switch-mode power supplies, particularly affecting communication technologies like weld circuit communication, necessitating large and expensive filtering components to comply with regulatory standards.
Innovation Solution
Implementing hysteretic mode boost voltage control to mitigate noise by switching to a burst mode operation during idle states, reducing noise without additional hardware, and enhancing signal-to-noise ratio in communication bands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional switch-mode power supplies are used in welding systems, then power conversion is achieved, but broad spectrum noise is generated that affects communication functions
Solution Approach 1:
The patent applies periodic action by implementing burst mode operation where the boost converter operates in discrete bursts rather than continuously. The controller enables the boost converter for a first duration during idle states, then disables it for a second duration, creating periodic on-off cycles. This periodic operation reduces broad spectrum noise while maintaining necessary power conversion capability during idle states.
2Reliability
If filtering components are added to reduce noise, then communication performance improves, but device complexity and cost increase
Solution Approach 1:
The patent converts the harmful noise-generating operation into a beneficial noise-reducing operation by utilizing the idle states of the welding system. During idle states, the controller actively manages the boost converter to operate in burst mode, which inherently reduces noise. This transforms the previously harmful continuous operation into a beneficial periodic operation that reduces noise without requiring additional filtering components.
3Object-generated harmful factors
If burst mode operation is implemented during idle states, then noise emissions are reduced, but power delivery may be affected
Solution Approach 1:
The patent applies dynamics by making the boost converter operation adaptive based on system state. The controller dynamically switches between continuous operation during active welding and burst mode operation during idle states. This dynamic adjustment ensures that noise reduction is applied only when necessary (during idle states), while maintaining full power delivery capability during active welding operations.
Solution Approach 2:
The patent changes the operational parameters of the boost converter based on system conditions. During idle states, the controller modifies the duty cycle and timing parameters to create burst mode operation with specific on-duration and off-duration. This parameter change reduces noise emissions during idle states while the system retains the ability to return to normal continuous operation parameters when welding activity resumes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves communication performance, reduces noise emissions, and ensures regulatory compliance by effectively managing noise in welding systems, particularly in idle states, without the need for additional hardware.
Implementation Method 1
the control circuitry is configured to apply noise mitigation for reducing or eliminating noise in the weld circuit communication, and wherein applying the noise mitigation comprises using hysteretic voltage control when the welding-type power source is at idle
Data Source
AI summary
Systems and methods are provided for hysteretic mode boost voltage control for reduced broad spectrum noise emission.