Welding Power Supply Pulse Control for Open-Circuit Voltage Limits
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Solution Overview
Problem
Welding-type power supplies face challenges in maintaining output levels within predefined limits, especially when dealing with changes in load and open circuit voltage conditions, which can affect the quality of welding operations and compliance with industrial standards.
Innovation Solution
A welding-type system with a controller that monitors pulsed output signals, adjusts pulse intervals, and identifies open circuit voltage conditions to ensure the RMS value remains within threshold levels, using a switched mode power supply to provide pulsed or constant voltage outputs based on the operational needs of the wire feeder and welding torch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the power supply provides high voltage output to drive the wire feeder, then the wire feeder operation is ensured, but the open circuit voltage may exceed safety thresholds
Solution Approach 1:
The patent applies periodic pulsed output instead of continuous high voltage. The controller delivers voltage in controlled pulses with specific duty cycles, allowing the wire feeder to operate reliably while keeping the RMS voltage within safe thresholds. The pulsed nature ensures that peak voltages are sufficient for wire feeder operation while average power delivery remains controlled.
Solution Approach 2:
The patent dynamically changes voltage parameters based on operational conditions. The controller adjusts pulse width, frequency, and duty cycle to maintain RMS voltage within thresholds while providing sufficient peak voltage for wire feeder operation. This parameter modulation resolves the contradiction between ensuring wire feeder operation and preventing excessive open circuit voltage.
2Adaptability or versatility
If the power supply adjusts output to accommodate load changes, then the system adaptability is improved, but the output level may fluctuate outside predefined limits
Solution Approach 1:
The patent implements feedback control where the controller continuously monitors output voltage and load conditions. Based on this feedback, the controller dynamically adjusts pulse parameters to maintain RMS voltage within predefined thresholds while accommodating load changes. This closed-loop control ensures both adaptability to load variations and reliability of output level maintenance.
Solution Approach 2:
The patent employs dynamic adjustment of output parameters rather than static settings. The controller adapts pulse width, frequency, and duty cycle in real-time based on load conditions, enabling the system to accommodate varying loads while maintaining output levels within specified limits through continuous optimization.
3Manufacturing precision
If the controller monitors and adjusts pulsed output signal continuously, then the output quality is improved, but the system complexity increases
Solution Approach 1:
The patent integrates multiple functions within a single controller unit. The controller simultaneously performs monitoring, calculation, determination of wire feeder state, and adjustment of pulse parameters. This multi-functional integration improves output signal quality through comprehensive control while minimizing the increase in overall system complexity by consolidating control functions.
Data Source
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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.