Welding Power Supply Pre-Regulator Control for Variable DC Bus Voltage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding power supplies experience excessive power losses and voltage stress due to the pre-regulator circuit always providing a pre-regulated bus voltage greater than the expected input voltage, leading to inefficient operation and potential reliability issues.
Innovation Solution
The pre-regulator circuit 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 selected weld processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the pre-regulator circuit always provides a pre-regulated bus voltage greater than the expected input voltage, then the power supply can operate with a fixed regulated voltage level, but excessive power losses and voltage stress occur
Solution Approach 1:
The pre-regulator circuit is configured to dynamically adjust the pre-regulated bus voltage level based on the detected input voltage level and operating conditions. The controller selectively enables different pre-regulated voltage levels (first, second, or third levels) corresponding to different input voltage ranges, allowing the system to adapt rather than maintain a fixed voltage, thereby reducing power losses and voltage stress.
Solution Approach 2:
The system changes the voltage parameter of the pre-regulated bus based on input conditions. The controller detects the input voltage level and selectively provides different pre-regulated voltage levels (first level for higher input voltages, second level for medium voltages, third level for lower voltages), optimizing the voltage parameter to match operating conditions and reduce energy losses.
2Device complexity
If the pre-regulator circuit always provides a pre-regulated bus voltage greater than the expected input voltage, then voltage regulation is simplified, but voltage stress increases leading to reliability issues
Solution Approach 1:
The pre-regulator circuit dynamically adjusts the pre-regulated bus voltage level based on detected input voltage levels and operating conditions. The controller selectively enables different voltage levels (first, second, or third levels) corresponding to different input voltage ranges, allowing the system to adapt rather than maintain a fixed high voltage, thereby reducing voltage stress and improving reliability.
Solution Approach 2:
The system changes the voltage parameter of the pre-regulated bus to match operating conditions. The controller detects input voltage level and selectively provides different pre-regulated voltage levels, optimizing the voltage parameter to reduce stress on components and improve system reliability.
3Loss of energy
If the pre-regulator circuit provides multiple pre-regulated voltage levels based on input voltage ranges, then power losses and voltage stress are reduced, but control complexity increases
Solution Approach 1:
The controller detects the input voltage level and uses this feedback information to selectively enable the appropriate pre-regulated voltage level. This feedback mechanism allows the system to automatically adjust to optimal voltage levels based on real-time conditions, reducing power losses while maintaining manageable control complexity through automated decision-making.
Solution Approach 2:
The pre-regulator circuit is designed to perform multiple functions by providing different pre-regulated voltage levels (first, second, and third levels) based on operating conditions. This multi-functionality allows a single circuit to optimize performance across various input voltage ranges, reducing power losses without requiring separate circuits for each voltage level.
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 power losses and voltage stress, improving the efficiency and reliability of the welding power supply by optimizing the pre-regulated bus voltage based on input voltage and weld process requirements.
Implementation Method 1
Pre-regulator circuits are sometimes used to regulate an input voltage of the input power to some pre-regulated voltage level that is always the same, regardless of the input voltage
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.