Welding Power Supply Pulse Conditioning for OCV RMS Control
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Solution Overview
Problem
Power supplies for welding and related equipment face challenges in maintaining output levels within predefined limits due to varying load conditions and open circuit voltage (OCV) changes, which can lead to improper operation and non-compliance with industrial standards.
Innovation Solution
A welding-type system with a controller that monitors and adjusts the pulsed output signal of a power supply to maintain an RMS value within a predetermined threshold, detects OCV conditions, and adjusts the pulse interval or frequency to ensure compliance with industrial standards, using a switched mode power supply and sense voltage circuit to manage power delivery to a wire feeder and welding torch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power supply provides high voltage output to drive the wire feeder and welding torch, then the power delivery capability is improved, but the output may exceed predefined voltage limits under open circuit conditions
Solution Approach 1:
The system dynamically adjusts the pulse interval of the output signal based on real-time monitoring of voltage levels and load conditions. When an open circuit condition is detected (voltage exceeds threshold), the controller increases the pulse interval to reduce the RMS voltage. When a load is detected, the controller decreases the pulse interval to maintain proper power delivery. This dynamic adjustment resolves the contradiction between maintaining high power delivery capability and preventing excessive voltage under open circuit conditions.
Solution Approach 2:
The system changes the temporal parameters of the output signal (pulse interval and frequency) in response to detected conditions. By adjusting these parameters, the system maintains compliance with voltage limits under open circuit conditions while ensuring adequate power delivery when loads are connected. The controller monitors voltage feedback and modifies the pulse characteristics to resolve the voltage limitation issue.
2Adaptability or versatility
If the power supply adjusts output signal frequently to accommodate load changes, then the adaptability to different operating conditions is improved, but the system complexity increases
Solution Approach 1:
The system employs periodic pulsed output signals instead of continuous output. This periodic action allows the system to naturally accommodate load changes by adjusting the pulse timing characteristics. The pulsed nature of the output simplifies the control mechanism compared to continuous adjustment, as the system can modify duty cycle and pulse interval to adapt to different conditions without requiring complex continuous control circuitry.
Solution Approach 2:
The system incorporates voltage feedback monitoring to detect load conditions and open circuit states. The controller uses this feedback information to automatically adjust the pulse interval and frequency. This feedback mechanism enables adaptable operation across different load conditions while maintaining relatively simple control logic, as the system responds to predefined voltage thresholds rather than requiring complex algorithms.
3Manufacturing precision
If the system monitors and adjusts pulsed output signal continuously, then the output level compliance with predefined limits is improved, but the energy consumption increases
Solution Approach 1:
The system applies partial action by using pulsed output signals rather than continuous output. The controller monitors voltage feedback continuously but only adjusts the output during pulse events. This approach maintains output compliance with predefined limits while reducing energy consumption compared to continuous high-level output. The system applies just enough power during each pulse to achieve the desired effect, avoiding excessive energy usage.
Data Source
AI summary
A welding-type system includes a wire feeder to provide an electrode wire to a welding-type torch. A welding-type power supply to provide power to one or both of the welding-type torch or the wire feeder. A controller is configured to control a sense voltage circuit to provide a sense voltage to charge a control capacitor, monitor a voltage feedback signal, determine that a wire feeder is activated based on a first change in the voltage feedback signal, control the switched mode power supply to provide a constant voltage output signal during a welding operation, control the switched mode power supply to provide the pulsed power output in response to completion of the welding operation, determine that the wire feeder is deactivated based on a second change in the feedback signal, adjust a pulse rate of the output signal to achieve an RMS value below a predetermined RMS level.