Weld Cable Impedance Measurement for Remote Arc Voltage Compensation
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Solution Overview
Problem
Welding systems face challenges in accurately measuring the impedance of weld cables, particularly when the welding location is distant from the power source, leading to significant voltage drops and inefficiencies in power delivery.
Innovation Solution
The system includes a power supply with communication circuitry to transmit commands to a welding device to close a switch, generating a controlled voltage signal with limited current to calculate resistance and inductance of the weld circuit, allowing for impedance measurement at any time, even when not welding, and using this data to adjust the power output for optimal voltage delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If weld cables are used to connect power source to remote welding location, then welding accessibility is improved, but voltage drop increases
Solution Approach 1:
The system performs preliminary measurement of weld cable impedance before welding operations begin. By measuring the resistance and inductance of the cable in advance, the power source can pre-calculate compensation values and adjust output parameters beforehand, ensuring optimal voltage delivery to remote welding locations without energy loss during actual welding
2Device complexity
If weld cable impedance is not measured, then system simplicity is maintained, but power delivery accuracy deteriorates
Solution Approach 1:
The power source is designed with multi-functionality, integrating both welding power delivery and impedance measurement capabilities into a single device. The measurement functions use existing power source components (output terminals, control circuitry) to perform cable characterization, eliminating the need for separate measurement equipment while maintaining system simplicity
Solution Approach 2:
The power source performs self-diagnosis by automatically measuring weld cable impedance using its own output circuitry. The system generates test signals through its power conversion circuitry, measures the resulting voltage and current, and calculates cable parameters without requiring external measurement devices, thereby maintaining simplicity while achieving high measurement precision
3Measurement precision
If impedance measurement is performed during welding, then real-time accuracy is improved, but welding continuity is disrupted
Solution Approach 1:
The system implements periodic impedance measurement at predetermined intervals during welding operations rather than continuous measurement. This allows brief measurement cycles to occur periodically, providing updated cable parameter data without continuously interrupting the welding arc, thus maintaining both measurement accuracy and welding continuity
Solution Approach 2:
Impedance measurements are performed preliminarily before welding begins and cached for use during welding operations. This preliminary characterization of the cable allows the power source to use stored impedance values throughout the welding process, eliminating the need for measurements during welding and completely preserving welding continuity while still providing accurate power delivery
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
This solution enables precise measurement and compensation for weld cable impedance, ensuring consistent and efficient power delivery to the welding torch, reducing voltage drops and improving welding performance.
Implementation Method 1
generating a controlled voltage signal with limited current to calculate resistance and inductance of the weld circuit
Data Source
AI summary
Welding power supplies, wire feeders, and systems to measure a weld circuit resistance via communications over the weld circuit are disclosed. An example welding-type power supply includes: a power conversion circuitry configured to: convert input power to output a signal via a weld circuit; and convert the input power to output welding-type power via the weld circuit; a voltage monitor configured to measure a power supply output voltage of the signal; communications circuitry configured to receive, via the weld circuit, a communication of a second voltage measurement; and control circuitry configured to: determine a resistance and/or and inductance of a portion of the weld circuit based on the power supply output voltage measurement, the second voltage measurement, and a weld circuit current.