Welding Power Supply Pre-Regulator Switching for DC Bus Loss Reduction
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Solution Overview
Problem
Conventional welding power supplies suffer from excessive power losses and voltage stress due to the constant provision of a pre-regulated bus voltage greater than expected input voltage, which reduces efficiency and reliability.
Innovation Solution
The pre-regulator circuit in the welding power supply is configured to provide two or more pre-regulated DC bus voltages or an unregulated DC bus based on input voltage levels and operating conditions, reducing power losses and voltage stress by adjusting the pre-regulated bus voltage according to input voltage ranges and weld processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the pre-regulator circuit provides a constant pre-regulated bus voltage greater than the minimum expected input voltage, then the power supply can operate across a wide input voltage range, but excessive power losses and voltage stress occur reducing efficiency and reliability
Solution Approach 1:
The pre-regulator circuit dynamically adjusts the pre-regulated bus voltage level based on the detected input voltage level. When input voltage is high, the pre-regulator provides a lower pre-regulated voltage; when input voltage is low, it provides a higher pre-regulated voltage. This dynamic adjustment optimizes power conversion efficiency across the entire input voltage range while reducing unnecessary power losses and voltage stress on components.
Solution Approach 2:
The system changes the operating parameters of the pre-regulator circuit based on input conditions. Specifically, the pre-regulated bus voltage parameter is varied according to the input voltage level, allowing the power supply to maintain optimal efficiency across different input voltage ranges without incurring excessive power losses or voltage stress.
2Adaptability or versatility
If the pre-regulator circuit provides a constant pre-regulated bus voltage greater than the minimum expected input voltage, then the power supply can operate across a wide input voltage range, but voltage stress increases reducing reliability
Solution Approach 1:
The pre-regulator circuit dynamically adjusts the pre-regulated bus voltage level based on the detected input voltage level. When input voltage is high, the pre-regulator provides a lower pre-regulated voltage; when input voltage is low, it provides a higher pre-regulated voltage. This dynamic adjustment optimizes power conversion efficiency across the entire input voltage range while reducing unnecessary power losses and voltage stress on components.
Solution Approach 2:
The system changes the operating parameters of the pre-regulator circuit based on input conditions. Specifically, the pre-regulated bus voltage parameter is varied according to the input voltage level, allowing the power supply to maintain optimal efficiency across different input voltage ranges without incurring excessive power losses or voltage stress.
3Stability of the object's composition
If the pre-regulator circuit operates continuously to provide regulated voltage, then voltage regulation is maintained, but power losses increase reducing efficiency
Solution Approach 1:
The pre-regulator circuit operates selectively rather than continuously. It activates only when the input voltage falls within a specific range that benefits from pre-regulation. When the input voltage is already within the acceptable operating range, the pre-regulator remains inactive, avoiding unnecessary power losses while still maintaining proper voltage regulation when needed.
Solution Approach 2:
The pre-regulator circuit dynamically adjusts the pre-regulated bus voltage level based on the detected input voltage level. When input voltage is high, the pre-regulator provides a lower pre-regulated voltage; when input voltage is low, it provides a higher pre-regulated voltage. This dynamic adjustment optimizes power conversion efficiency across the entire input voltage range while reducing unnecessary power losses and voltage stress on components.
Data Source
AI summary
Apparatus, systems, and/or methods are disclosed relating to a welding-type power supply with a pre-regulator circuit configured to provide a pre-regulated direct current (DC) bus at two or more voltage levels, responsive to various operating conditions. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus voltage at one voltage level for certain input line voltages, weld processes, and/or target weld output levels, and at another voltage level for other input line voltages, weld processes, and/or target weld output levels. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus voltage for certain input line voltages, weld processes, and/or target weld output levels and an unregulated DC bus voltage at other input line voltages, weld processes, and/or target weld output levels. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus at a service voltage in response to detecting a service mode of operation, and/or at an idle voltage in response to detecting an idle mode of operation.