Welding Power Supply Circuit With Integrated Secondary-Side Rectification
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Solution Overview
Problem
Conventional welding power supply topologies suffer from inefficiencies such as excess losses, idle semiconductor devices, and the need for additional circuitry to handle reactive energy, leading to heat loss, increased costs, and complex thermal management.
Innovation Solution
A welding power supply circuit that integrates rectifier and commutation functions in semiconductor devices on the secondary side of the isolation barrier, using a transformer with secondary windings and switching elements controlled by a control circuit to output positive or negative voltages without a separate rectifier stage, and employs a reverse power transfer mode to manage reactive energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional full-bridge or half-bridge power supply circuits are used, then welding power can be supplied, but excess losses occur and idle semiconductor devices generate unnecessary heat
Solution Approach 1:
The patent combines the rectifier stage and commutation stage into a single integrated circuit on the secondary side of the isolation barrier. The semiconductor devices perform both rectification and commutation functions simultaneously, eliminating idle devices and reducing heat loss while maintaining welding efficiency.
Solution Approach 2:
The semiconductor devices in the integrated circuit are designed to perform multiple functions: rectification of AC voltage and commutation of welding current. This multi-functionality ensures that all semiconductor devices are actively utilized during operation, eliminating idle devices and their associated heat losses.
2Device complexity
If separate rectifier and commutation stages are used, then welding power can be supplied, but additional circuitry is required increasing complexity and cost
Solution Approach 1:
The patent merges the rectifier stage and commutation stage into a single integrated circuit on the secondary side. This consolidation reduces the number of separate components and interconnections, simplifying the overall circuit while maintaining reliable arc stability through coordinated control of all semiconductor devices.
3Loss of energy
If reactive energy is not managed on the secondary side, then circuit simplicity is maintained, but energy efficiency decreases
Solution Approach 1:
The integrated circuit on the secondary side autonomously manages reactive energy by incorporating both rectifier and commutation functions. The circuit self-regulates the flow of reactive energy through its semiconductor devices, improving energy efficiency without requiring external energy management systems.
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 heat loss, simplifies thermal management, lowers costs, and enhances efficiency by balancing current and heat dissipation across all semiconductor devices, enabling compact design and improved arc stability.
Implementation Method 1
a transformer with secondary windings and switching elements controlled by a control circuit
Implementation Method 2
integrate rectifier and commutation functions in semiconductor devices on the secondary side of the isolation barrier
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A welding-type power supply comprising a transformer, first to fourth switching elements and a control circuit. The transformer has first and second secondary windings. The first switching element coupled between the first secondary winding and a first output terminal of the welding-type power supply. The second switching element coupled between the second secondary winding and the first output terminal of the welding-type power supply. The third switching element coupled between the first secondary winding and a second output terminal of the welding-type power supply. The fourth switching element coupled between the second secondary winding and the second output terminal of the welding-type power supply. The control circuit is configured to output a welding voltage having a first polarity by controlling the first switching element and the second switching element to operate as a center tap between the first and second secondary windings while the third switching element and the fourth switching element operate as rectifiers. The control circuit is further configured to output the welding voltage having a second polarity by controlling the third switching element and the fourth switching element to operate as the center tap between the first and second secondary windings while the first switching element and the second switching element operate as rectifiers.