Welding Machine Auxiliary Power Supply Surge Control
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Solution Overview
Problem
Welding machines face challenges in operating with varying power sources, and there is a need for an auxiliary power supply that can manage surges or spikes in current draw, especially when using power tools that require 115 VAC, which may not be available in all environments.
Innovation Solution
An electric welding machine with an auxiliary power supply that includes a main transformer with two secondary windings, an AC to DC converter, and a pulse width modulation circuit to monitor and control the power output, reducing available power during surges or spikes by adjusting pulse widths to maintain a sinusoidal waveform and prevent interference with the welding output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the auxiliary power supply provides full power output, then power tools can operate normally, but welding output quality deteriorates due to current surges and spikes
Solution Approach 1:
The patent applies periodic action by using pulse width modulation (PWM) to intermittently switch the auxiliary power supply output. The PWM circuit rapidly switches the power delivery in periodic pulses, adjusting the duty cycle to control average power while preventing continuous surges that would interfere with welding operations. This periodic switching allows the system to provide sufficient power for tools during normal operation while preventing harmful current spikes during welding.
Solution Approach 2:
The patent implements dynamics by making the auxiliary power supply adaptive and variable rather than fixed. The system dynamically adjusts the auxiliary power output based on real-time detection of welding states and power demands. The control circuit continuously monitors conditions and modifies the PWM duty cycle accordingly, allowing the auxiliary supply to transition between different power levels to balance tool operation needs with welding quality requirements.
2Ease of operation
If the auxiliary power supply allows high starting currents for power tools, then tools can start properly, but welding output is interfered with due to current spikes
Solution Approach 1:
The patent applies preliminary anti-action by implementing a surge limit circuit that detects and preemptively restricts excessive current draws before they can interfere with welding operations. The system monitors the auxiliary power output and automatically applies current limiting when surge conditions are detected, preventing the harmful interaction between tool starting currents and welding output while still allowing normal startup sequences.
Solution Approach 2:
The patent implements feedback through a control circuit that continuously monitors the auxiliary power supply output and welding circuit conditions. The feedback mechanism detects current surge conditions and automatically adjusts the PWM duty cycle to limit surges, creating a closed-loop control system that maintains welding stability while permitting necessary tool operation. The system responds to real-time conditions by dynamically modifying power delivery characteristics.
3Stability of the object's composition
If the auxiliary power supply operates independently, then it can provide consistent power, but it cannot respond to welding load changes and causes power loss
Solution Approach 1:
The patent applies universality by designing the auxiliary power supply as a multi-functional system that serves both standalone power supply and welding-assist functions. The PWM-controlled auxiliary supply can operate in different modes depending on system conditions - providing stable independent power when welding is not active, and automatically coordinating with welding loads when active, thus eliminating the need for separate independent and welding-linked power systems.
Solution Approach 2:
The patent implements feedback by connecting the auxiliary power supply control to welding circuit monitoring. The system detects welding load changes through feedback signals and automatically adjusts auxiliary power delivery accordingly. This feedback mechanism allows the auxiliary supply to reduce or eliminate power delivery during welding operations, preventing energy loss and power interference while maintaining stable operation during non-welding periods.
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
The solution ensures stable operation of welding machines by managing power spikes and providing a consistent 115 VAC output for auxiliary power tools, maintaining the quality of welding output while accommodating different power sources and reducing the impact of high starting currents from tools like grinders.
Implementation Method 1
a main transformer that provides isolation from the input. The main transformer includes a first secondary winding in circuit communication with a welder power output and a second secondary winding in circuit communication with an auxiliary power supply
Implementation Method 2
an AC to DC converter
Implementation Method 3
an inverter
Implementation Method 4
a pulse width modulation circuit for providing a pulsed input to a filter
Implementation Method 5
The pulsed input to the filter provides a maximum available auxiliary power output under normal conditions and reduces the available auxiliary power output if there is a surge or spike on the auxiliary power output
Data Source
AI summary
A electric welding machine having an auxiliary power output, and a method for controlling the auxiliary power output on a welding machine is provided. In one embodiment, the system includes a main transformer having a first secondary winding in circuit communication with a welder power output and a second secondary winding in circuit communication with an auxiliary power supply having an auxiliary power output. The auxiliary power supply includes an input for monitoring the welder power output to determine if the welder power output is on; circuitry for determining whether a surge or spike in demand is present at the auxiliary power output; and circuitry for limiting the available power to the auxiliary power output if certain conditions are satisfied. One method includes monitoring the demand on an auxiliary power output, monitoring a welding power output, determining whether there is a spike in the demand on the auxiliary power output that is above a first limit, and reducing the available power to the auxiliary power output if the spike is above the first limit and the welding power output is energized.