Weld Cable Feedback Control for Arc Voltage Compensation
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Solution Overview
Problem
Welding applications with large distances between the power source and the welding location require operators to frequently walk back and forth to adjust settings, and long weld cables cause significant voltage drops, necessitating accurate weld voltage compensation without additional cables or unreliable wireless communications.
Innovation Solution
Welding power supplies and wire feeders communicate via the weld cable to measure circuit resistance and adjust voltage using a feedback loop, eliminating the need for additional control cables and improving voltage accuracy at the welding arc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If long weld cables are used to extend the welding location far from the power source, then the welding location flexibility is improved, but voltage drop increases
Solution Approach 1:
The system measures the actual voltage at the welding arc and feeds this information back to the power source through the weld cable. The power source uses this feedback to adjust its output and compensate for voltage drops in the cable, ensuring accurate weld voltage despite long cable lengths
Solution Approach 2:
The patent replaces mechanical adjustment systems with electronic communication over the weld cable. Instead of requiring physical presence at the power source for adjustments, the system uses electrical signals transmitted through the existing weld cable to communicate voltage information and control parameters
2Adaptability or versatility
If additional control cables are added to enable remote adjustments, then communication capability is improved, but device complexity increases
Solution Approach 1:
The weld cable serves multiple functions simultaneously: it delivers welding power to the arc and transmits communication signals for voltage measurement and control adjustments. This multi-functionality eliminates the need for separate control cables while maintaining full communication capability
Solution Approach 2:
The system merges the power transmission function and communication function into a single weld cable. By combining these functions, the patent reduces the number of cables required while enabling remote monitoring and adjustment capabilities
3Ease of operation
If wireless communications equipment is used for remote adjustments, then operator convenience is improved, but reliability decreases in weld environment
Solution Approach 1:
The weld cable acts as an intermediary medium for communication between the power source and the welding location. By using the existing electrical connection as the communication channel, the system avoids unreliable wireless communication while maintaining operator convenience for remote adjustments
4Measurement precision
If operators frequently walk back to the power source for adjustments, then control accuracy is improved, but time consumption increases
Solution Approach 1:
The system continuously measures the actual weld voltage and feeds this information back to enable automatic adjustments. This eliminates the need for operators to physically return to the power source for voltage checks and adjustments, maintaining control accuracy while significantly reducing time consumption
Solution Approach 2:
The welding system performs self-diagnosis and self-adjustment by automatically measuring weld voltage and compensating for variations. This self-service capability eliminates manual intervention for routine adjustments, improving both time efficiency and maintaining precision
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 system ensures accurate weld voltage at the arc without additional cables, simplifying operations and reducing voltage drop errors, thereby enhancing welding efficiency and precision.
Implementation Method 1
the welder must pull and monitor a long welding power cable extending from the power source to the welding location
Implementation Method 2
weld cables (and, particularly, long weld cables) introduce a non-negligible voltage drop between the power source and the site of the work
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 converter configured to: convert input power to output a current pulse 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 current pulse; a receiver circuit configured to receive, via the weld circuit, a communication comprising a second voltage measurement; and a controller configured to: determine a resistance of a portion of the weld circuit based on the power supply output voltage measurement, the second voltage measurement, and a weld circuit current measurement; and control the power converter to convert the input power to output the welding-type power based on a weld voltage setpoint and the impedance.