Welding Arc Starting Control with Reduced Open Circuit Voltage
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Solution Overview
Problem
Conventional welding power supplies face inefficiencies and delayed arc initiation due to high open circuit voltage when not in use, leading to energy waste and suboptimal performance, especially in sub-optimal welding conditions.
Innovation Solution
The system employs a series of voltage pulses with controlled duration and repetition to reduce average open circuit voltage, transitioning to welding-type output upon arc detection, and adjusts voltage and current to stabilize the arc during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional welding power supplies maintain high open circuit voltage during non-welding periods, then arc starting capability is ensured, but energy consumption increases and equipment standards compliance deteriorates
Solution Approach 1:
The patent applies periodic action by transitioning the power supply from continuous high voltage output to pulsed voltage output during non-welding periods. The controller switches between a first output state (high open circuit voltage) and a second output state (reduced open circuit voltage) based on welding detection, creating a periodic on-demand power delivery pattern that reduces energy consumption while maintaining arc starting capability when needed.
2Loss of energy
If open circuit voltage is reduced to comply with equipment standards, then energy waste decreases, but arc starting speed deteriorates
Solution Approach 1:
The patent applies preliminary action by maintaining the power supply in a first output state with high open circuit voltage during non-welding periods, preparing the system in advance for rapid arc initiation. When welding is detected, the controller quickly transitions to the second output state, ensuring that the arc starting capability is already prepared rather than needing to build up from a reduced voltage state.
3Productivity
If continuous welding-type power is output during non-welding periods, then arc initiation response is improved, but power consumption increases
Solution Approach 1:
The patent applies dynamics by making the power supply output state variable rather than fixed. The controller dynamically adjusts between a first output state (welding-type power with high open circuit voltage) and a second output state (reduced open circuit voltage) based on real-time welding detection, allowing the system to optimize between response capability and power consumption according to actual operational needs.
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 approach reduces energy consumption during non-welding periods, enhances arc initiation speed, and maintains performance in challenging conditions like oxide or rust on the workpiece, improving overall welding efficiency and stability.
Implementation Method 1
power conversion circuitry configured to convert input power to welding-type power
Implementation Method 2
provide welding-type arc starting and stabilization with reduced open circuit voltage
Data Source
AI summary
Systems and methods to provide welding-type arc starting and stabilization with reduced open circuit voltage are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output a voltage pulse at a first voltage; determine whether the power conversion circuitry outputs current during the voltage pulse; in response to determining that there is less than a threshold output current during the voltage pulse, control the power conversion circuitry to turn off an output or output a second voltage that is less than the first voltage; and in response to determining that the power conversion circuitry outputs at least the threshold output current during the voltage pulse, control the power conversion circuitry to output the welding-type power.