Arc Welding Voltage Feedback Circuit for Magnetic Noise Cancellation
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Solution Overview
Problem
High electrical currents in power supply cables of arc welding apparatuses generate magnetic fields that induce noise and distortions in measurement wires, affecting the accuracy of voltage feedback signals and the power supply's ability to regulate voltage between the welding head and workpiece.
Innovation Solution
The implementation of feedback circuitry with a reference wire configured as a twisted pair or using a transformer to subtract noise from the measurement wire, ensuring that both wires experience similar disturbances, allowing for accurate noise compensation and voltage regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If measurement wires are used to provide feedback signals, then voltage regulation capability is improved, but measurement precision deteriorates due to magnetic field induced noise
Solution Approach 1:
A reference wire is introduced as an intermediary element that carries only the magnetic field induced noise without the actual voltage signal. This reference wire acts as a mediator to separate the noise component from the measurement signal, allowing the noise to be identified and subtracted while preserving the accurate voltage measurement.
Solution Approach 2:
The system uses feedback by continuously monitoring the reference wire signal and subtracting it from the measurement wire signal. This feedback mechanism dynamically compensates for magnetic field induced noise, maintaining measurement precision while preserving the voltage regulation capability provided by the measurement wires.
2Power
If power supply cables carry high electrical currents, then power delivery capability is improved, but harmful factors increase due to magnetic field generation
Solution Approach 1:
The magnetic field induced noise, which is normally a harmful effect, is converted into a useful signal by using the reference wire to carry this noise. The reference wire captures the magnetic field interference and transforms it into a compensatable signal that can be subtracted from the measurement, thereby converting the harmful noise into a beneficial reference for noise cancellation.
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 solution effectively reduces and eliminates noise in voltage measurement wires, enabling the power supply to accurately regulate voltage, thereby improving the precision and reliability of the welding process.
Implementation Method 1
High electrical currents in the power supply cables give rise to magnetic fields. The magnetic fields induce disturbances/noise on the measurement wires.
Implementation Method 2
feedback circuitry includes subtraction circuitry to subtract noise of a reference wire from a noisy head voltage of a measurement wire
Data Source
AI summary
Methods and systems to reduce distortions induced in a voltage measurement wire. In an embodiment, a measurement wire is coupled to a head of an arc welding apparatus and to a feedback circuit to provide a head voltage and noise induced on the measurement wire to the feedback circuit. A reference wire is coupled to a reference node and to the feedback circuit to provide noise induced on the reference wire to the feedback circuit. The reference node may be proximate to and electrically isolated from the head, and the measurement wire and the reference wire may be arranged adjacent to one another (e.g., as a twisted pair), so that the similar distortions are induced in the measurement wire and the reference wire. The feedback circuit determines the head voltage as a difference between noise of the reference wire and the head voltage and noise of the first measurement wire.