Welding Power Supply Waveform Control for Stable Frequency-Amperage Ranges

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Solution Overview

Problem

Conventional welding-type power supplies face issues with poor welding performance due to resistance and inductance in certain parameter ranges, particularly when using AC and DC pulse waveforms.

Innovation Solution

The system automatically selects or adjusts AC and DC pulse parameters based on empirically determined relationships between frequency and amperage, providing indications of acceptable parameter ranges to operators, and includes power conversion circuitry to convert input power to suitable welding-type power.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If AC and DC pulse waveforms are used in conventional welding power supplies, then welding flexibility and control capability are improved, but poor welding performance occurs due to resistance and inductance in certain parameter ranges

Engineering Contradiction:

Improvewelding flexibilityVSAvoidwelding performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system dynamically adjusts welding parameters (frequency, amperage, duty cycle) in real-time based on feedback from sensors monitoring the welding process. This allows the power supply to adapt to changing conditions and avoid poor performance regions caused by resistance and inductance, maintaining reliable welding across varying parameters.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention systematically varies multiple parameters (frequency, amperage, pulse width, duty cycle) to identify and avoid poor welding performance regions. By changing parameters dynamically rather than using fixed settings, the system can navigate around problematic parameter combinations caused by circuit resistance and inductance while maintaining welding flexibility.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If operators manually select welding parameters, then ease of operation is maintained, but poor welding conditions occur due to incorrect parameter selection in certain frequency and amperage ranges

Engineering Contradiction:

Improveparameter selection simplicityVSAvoidwelding performance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system incorporates sensors that monitor welding parameters and performance in real-time, providing feedback to a control algorithm. This feedback mechanism allows the system to automatically adjust parameters or alert operators when approaching poor performance regions, combining ease of operation with reliable welding outcomes.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The welding power supply performs self-diagnosis and automatic parameter optimization by monitoring its own output and the welding process. The system identifies poor performance regions caused by resistance and inductance and automatically adjusts parameters to avoid them, reducing reliance on operator expertise while maintaining welding quality.

Inventive Principle:

Principle #25Self-service

3Device complexity

If fixed frequency and amperage settings are used, then device complexity is reduced, but welding performance deteriorates in certain parameter ranges due to resistance and inductance effects

Engineering Contradiction:

Improvecontrol system complexityVSAvoidwelding performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Rather than using fixed settings, the system employs dynamic parameter adjustment through programmable controllers that can modify frequency, amperage, and pulse characteristics in real-time. This dynamic approach adds controlled complexity to avoid the poor performance regions caused by circuit resistance and inductance.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

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 the likelihood of poor welding conditions by optimizing frequency and amperage settings, ensuring effective welding performance across various parameter combinations.

Implementation Method 1

power conversion circuitry configured to convert input power to welding-type power

Methodology Applied

Scientific EffectPower conversion:

Data Source

PatentUS12390873B2Systems and methods to control welding-type power supplies using AC waveforms and/or DC pulse waveforms

Publication Date: 2025.08.19 ILLINOIS TOOL WORKS INC

AI summary

An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power having at least one of an alternating current (AC) waveform or a pulse waveform; an interface configured to receive an input representative of a selected frequency of the AC waveform or the pulse waveform; and control circuitry configured to: determine an amperage parameter of the welding-type power; based on the amperage parameter, determine a range of frequencies of the AC waveform or the pulse waveform; control the interface to output an indication of the selected frequency with respect to the determined range of frequencies; and control the power conversion circuitry to output the welding-type power at the selected frequency and based on the amperage parameter.