Regulated Background Power Supply for Welding Arc Stability
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Solution Overview
Problem
Welding power supplies often fail to meet transient high voltage requirements during welding operations, leading to arc instability, outages, and improper welding due to their inability to provide sufficient power beyond the average or rated load conditions.
Innovation Solution
A welding power supply system incorporating a background circuit with an energy storage device and a fast-acting switch, regulated by a control circuit to supplement or take over the power output during transient high voltage events, ensuring stable arc maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the main inverter is designed to meet dynamic requirements with higher transformer turns ratio and higher currents, then transient high voltage requirements are satisfied, but power losses increase and device complexity increases
Solution Approach 1:
The power supply is divided into two independent circuits: a main power supply circuit for average load requirements and a background power supply circuit for transient high voltage requirements. This segmentation allows each circuit to be optimized for its specific function, avoiding the need for the main inverter to be over-designed for peak transient conditions, thereby reducing power losses and improving efficiency.
Solution Approach 2:
The background power supply circuit is pre-charged to a high voltage level during normal operation. When a transient high voltage event is detected, the pre-charged energy is immediately discharged through the fast acting switch to meet the transient requirement. This preliminary charging action eliminates the need for the main inverter to respond dynamically to transient spikes, reducing power losses.
2Reliability
If the main inverter is designed to meet dynamic requirements with higher transformer turns ratio and higher currents, then transient high voltage requirements are satisfied, but device complexity increases
Solution Approach 1:
The power supply is divided into two independent circuits: a main power supply circuit for average load requirements and a background power supply circuit for transient high voltage requirements. This segmentation allows each circuit to be optimized for its specific function, avoiding the need for the main inverter to be over-designed for peak transient conditions, thereby reducing power losses and improving efficiency.
Solution Approach 2:
The background power supply circuit acts as an intermediary that supplements the main power supply during transient events. Instead of making the main inverter more complex to handle transient conditions, the background circuit is introduced as a separate auxiliary system that activates only when needed, controlled by a simple voltage detection mechanism.
3Device complexity
If a welding power supply is not capable of providing transient voltage requirements, then device complexity is reduced, but arc stability deteriorates
Solution Approach 1:
The background power supply circuit is pre-charged to a high voltage level during normal operation. When a transient high voltage event is detected, the pre-charged energy is immediately discharged through the fast acting switch to meet the transient requirement. This preliminary charging action eliminates the need for the main inverter to respond dynamically to transient spikes, reducing power losses.
Solution Approach 2:
The control circuit continuously monitors the output voltage of the power supply. When a transient high voltage event is detected (voltage exceeds a predetermined threshold), the control circuit activates the background power supply circuit by closing the fast acting switch. This feedback mechanism ensures arc stability is maintained with simple control logic.
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 system effectively addresses transient voltage spikes, maintaining arc stability and preventing undesirable welding effects by providing the necessary power during high voltage requirements, even exceeding the main power supply's capabilities.
Implementation Method 1
an energy storage device adapted to be charged by the first power output to a programmable first voltage level
Data Source
AI summary
Welding power supplies with regulated background power supplies are disclosed. An example welding power supply includes a background circuit, which comprises: a power supply capable of outputting a first power output; an energy storage device configured to be charged by the first power output to a programmable first voltage level; a fast acting switch coupled to the energy storage device and configured to switch to restrict or allow voltage discharge from the energy storage device to welding electrodes; and a control circuit configured to selectively activate the power supply to output the first power output when the energy storage device is not charged to the regulated first voltage level, and further configured to actuate the fast acting switch to allow voltage discharge of the energy storage device from the regulated first voltage level to a controlled second voltage level when a transient high voltage event is detected.