Series-Secondary Transformer Circuit for Welding Arc Starting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional arc starting/stabilizing circuitry in welding systems is costly and complex due to the use of transformers, which also results in inefficiencies and high manufacturing challenges.
Innovation Solution
The use of multiple 1:1 transformers with primary winding turns coupled in parallel and secondary winding turns connected in series, along with a pulse generator, to output high voltage pulses for arc starting and stabilization, reducing complexity and cost while improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transformers are used in arc starting/stabilizing circuitry, then arc striking and stabilization can be achieved, but the system becomes costly and complex with manufacturing challenges
Solution Approach 1:
The patent divides the single transformer function into multiple smaller transformer units (first transformer and second transformer) that operate in parallel. Each transformer handles a portion of the total power, simplifying individual unit design and manufacturing while maintaining overall system capability for arc starting and stabilization.
Solution Approach 2:
The patent combines multiple transformer units with identical or similar specifications to achieve the required power output. By merging parallel transformer units, the system maintains reliability through redundancy while reducing the complexity of designing and manufacturing a single large, complex transformer.
2Reliability
If conventional transformers are used in arc starting/stabilizing circuitry, then arc striking and stabilization can be achieved, but manufacturing becomes difficult and costly
Solution Approach 1:
The patent segments the power transformation function into multiple identical or similar transformer units. This segmentation allows each unit to be manufactured using standardized processes, improving ease of manufacture compared to building a single custom large transformer, while the combined units provide the required reliability for arc operations.
Solution Approach 2:
The patent changes the approach from using a single transformer with high power rating to multiple transformers with lower individual power ratings. This parameter change enables the use of standardized, off-the-shelf transformer components that are easier and more cost-effective to manufacture and replace, while achieving the same overall system reliability.
3Reliability
If conventional transformers are used in arc starting/stabilizing circuitry, then arc striking and stabilization can be achieved, but power losses increase due to inefficiencies
Solution Approach 1:
The patent divides the power transformation into multiple parallel transformer channels. This segmentation allows each transformer to operate at optimal load points, improving individual efficiency. The combined effect of multiple efficient transformers reduces total power losses compared to a single large transformer operating under varying load conditions.
Solution Approach 2:
The patent configures the multiple transformer units to automatically share the load based on their operational characteristics. Each transformer self-regulates its output to maintain optimal efficiency, reducing the need for complex control systems and minimizing energy losses through intelligent self-balancing of the parallel configuration.
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 configuration simplifies the manufacturing process, reduces power losses, and enhances the efficiency of the arc starting/stabilizing circuitry, allowing for effective arc striking and stabilization in welding processes without the need for complex and expensive transformers.
Implementation Method 1
circuits may be configured to output high voltage, high frequency pulses to the weld circuit to enable arc striking
Implementation Method 2
a plurality of transformers configured to receive the voltage pulses and output the voltage pulses to a welding-type output circuit at a second voltage higher than the first voltage
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
An example arc starting/stabilizing circuit includes: a pulse generator configured to generate voltage pulses having a first voltage; and a plurality of transformers configured to receive the voltage pulses and output the voltage pulses to a welding-type output circuit at a second voltage higher than the first voltage, wherein: each of the plurality of transformers comprises one primary winding turn, one secondary winding turn, and a core configured to magnetically couple the primary winding turn and the secondary winding turn; the primary winding turns of the plurality of transformers are coupled to the pulse generator to receive the voltage pulses; and the secondary winding turns of the plurality of transformers are coupled in series and are configured to conduct welding-type current in the welding-type output circuit.