Welding Current Source With Segmented Secondary Winding
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Solution Overview
Problem
Conventional welding current sources with inverters face challenges in achieving high output voltage for reliable arc ignition and stabilization, especially at low currents, while adhering to safety regulations and minimizing component complexity.
Innovation Solution
Incorporating a current-limiting inductor on the secondary winding of the transformer, along with a load resistor and capacitor, to increase no-load voltage without exceeding safety limits, and using a coupled current-limiting inductor to reduce complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second secondary winding with higher leakage inductance is used to achieve higher output voltage, then arc ignition and stabilization are improved, but device complexity increases
Solution Approach 1:
The patent divides the secondary winding into two separate windings (first secondary winding and second secondary winding) with different turn ratios and leakage inductances. The first secondary winding (with fewer turns and lower leakage inductance) handles high-current welding operations, while the second secondary winding (with more turns and higher leakage inductance) provides higher voltage for arc ignition and low-current stabilization. This segmentation allows each winding to be optimized for its specific function without compromising the other.
2Reliability
If voltage-doubling circuits or switched-mode power supplies are used to achieve higher output voltage, then arc ignition is improved, but component complexity increases
Solution Approach 1:
The patent extracts the voltage multiplication function from complex external circuits (voltage-doubling circuits or switched-mode power supplies) and integrates it directly into the transformer structure through the second secondary winding. This winding is designed with a higher turn ratio and higher leakage inductance to naturally produce the required voltage boost for arc ignition, eliminating the need for additional complex circuitry while achieving the same functional result.
3Adaptability or versatility
If the number of turns on the second secondary winding is increased to achieve higher voltage, then output voltage range is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies different quality characteristics to different windings: the first secondary winding is designed with fewer turns optimized for high-current transmission, while the second secondary winding is designed with more turns optimized for higher voltage output. Each winding's parameters (turn count, wire gauge, placement) are locally optimized for its specific function, allowing the system to achieve a wide output voltage range without requiring extreme manufacturing precision across the entire transformer.
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 allows for improved arc ignition and stabilization with increased no-load voltage, while maintaining safety compliance and reducing component complexity, enabling efficient welding at low currents and high currents with reduced power consumption.
Implementation Method 1
The winding ratio of primary winding to secondary winding increases the current on the secondary side of the transformer to the high currents, of the order of several 100 A, required for welding
Implementation Method 2
To attenuate unwanted interference signals in the output voltage or the output current, a capacitor and a load resistor are often arranged at the output
Implementation Method 3
a welding current source for supplying of a welding current and a welding voltage at an output for the performance of an arc welding process
Data Source
AI summary
A welding current source for providing a welding current and a welding voltage at an output in order to carry out an arc welding process includes an input-side rectifier, an inverter, which is operated with a switching frequency, a transformer having a primary winding and at least two secondary windings, at least two rectifiers arranged between the secondary windings and the output, and at least one capacitor and one load resistor at the output. At least one current-limiting reactor is arranged on the second secondary winding and the load resistor for discharging the capacitor, which can be charged by the current-limiting reactor, the current-limiting reactor, and the capacitor are dimensioned in such a way that the maximum value of the no-load voltage at the output is greater than the voltage corresponding to the transmission ratio of the primary winding to the secondary winding of the transformer.