Weld Cable Equalization Using Low-Power Tone Measurement
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Solution Overview
Problem
The arrangement and characteristics of power cables in welding systems cause distortions in transmitted data, weld process current, and voltage, making it cumbersome to measure and compensate for static and dynamic characteristic impedances during operation.
Innovation Solution
A welding system with a low power transceiver coupled to the weld cable, which transmits and receives unmodulated tones to determine channel equalization filter coefficients, compensating for frequency and time-dependent amplitude and phase distortions using digital filter functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power cables are used to supply power in welding systems, then power transmission is achieved, but distortions occur in transmitted data, weld process current, and voltage
Solution Approach 1:
The patent introduces an intermediary measurement system consisting of a signal injector, voltage sensor, current sensor, and processor. This intermediary system measures the actual voltage and current at the cable output and compares them with expected values, thereby detecting distortions without interfering with the primary power transmission function of the cable.
Solution Approach 2:
The patent implements a feedback mechanism where the processor receives measured voltage and current data from the sensors, analyzes distortions, and generates compensation signals. This feedback loop enables continuous monitoring and correction of cable-induced distortions, improving the reliability of power transmission while maintaining the original power delivery capability.
2Measurement precision
If measurements are performed during welding operation to compensate for cable distortions, then measurement accuracy is improved, but system complexity increases
Solution Approach 1:
The patent merges the measurement functions into a single integrated processor that handles both voltage and current measurements. The voltage sensor and current sensor are coordinated through the same processor, which combines their data to compute distortion characteristics. This merging approach improves measurement precision while minimizing the increase in system complexity by using a unified control unit rather than separate systems for each measurement.
Data Source
AI summary
A welding system is provided. The welding system includes a low power transceiver configured to be coupled to a weld cable. The low power transceiver includes a low power transmitter, a low power receiver, and a first processor. The low power receiver is configured to transmit one or more unmodulated tones through the weld cable to a welding power supply. The low power receiver is configured to receive the one or more unmodulated tones through the weld cable from the welding power supply. The first processor is configured to determine one or more channel equalization filter coefficients related to the weld cable corresponding to a distortive characteristic of the weld cable.