Welding Wire Feeder With Local Power Conversion
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Solution Overview
Problem
Long power cables in welding systems introduce variable inductance, affecting the timing and amplitude of pulsed power in advanced MIG welding processes, leading to inconsistencies in the welding output.
Innovation Solution
A welding wire feeder system with power conversion circuitry that converts input power from a welding power source to a controlled waveform output, reducing the effect of inductance in the power cable and ensuring accurate and timely delivery of welding output to the torch, regardless of cable length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If long power cables are used to position welding location at remote distances from power source, then welding accessibility is improved, but inductance effects cause deterioration in pulse timing and amplitude accuracy
Solution Approach 1:
The wire feeder acts as an intermediary device between the power source and welding torch, incorporating local power conversion circuitry that generates controlled waveform output independently of the power cable characteristics. This mediator eliminates the harmful inductance effects by creating a new reference point for pulse generation at the wire feeder location.
Solution Approach 2:
The system segments the power delivery function by separating the main power source from the power conversion function. The wire feeder contains its own power conversion circuitry that receives power through the cable but independently generates the controlled waveform output, dividing the system into power supply and power conversion segments.
2Manufacturing precision
If power conversion circuitry is added to compensate for inductance effects, then pulse accuracy is improved, but device complexity increases
Solution Approach 1:
The patent merges the power conversion function with the wire feeder device, combining multiple functions (wire feeding, power conversion, and controlled waveform generation) into a single integrated unit. This reduces overall system complexity by eliminating the need for separate power conversion equipment.
Solution Approach 2:
The wire feeder is designed as a multi-functional device that simultaneously performs wire feeding and power conversion to controlled waveform output. This universal device eliminates the need for additional specialized equipment, reducing system complexity while maintaining pulse accuracy.
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
The system maintains the accuracy and response time of controlled waveform welding outputs, ensuring consistent weld quality even at remote locations from the power source, by dynamically adjusting voltage and amperage to compensate for inductance-induced delays.
Implementation Method 1
power conversion circuitry configured to receive the input power and to convert the input power to controlled waveform welding output
Data Source
AI summary
A welding wire feeder includes a welding wire feed drive configured to drive welding wire towards a welding application and wire feed control circuitry coupled to the welding wire feed drive. The wire feed control circuitry is also configured to control the drive of welding wire towards the welding application. The welding wire feeder also includes power conversion circuitry and welding process control circuitry coupled to the power conversion circuitry. The power conversion circuitry is configured to receive input power from a welding power source and to convert the input power to controlled waveform welding output. The welding process control circuitry is configured to provide control signals for conversion of the input power to the controlled waveform welding output. The welding wire feeder also includes a process operator interface coupled to the welding process control circuitry and configured to permit operator selection of a controlled waveform welding process.