Wire Feeder Feedback Over Weld Cables for Resistance Compensation
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Solution Overview
Problem
Welding applications often require operators to walk long distances to manage power cables, leading to inefficiencies and inaccuracies in weld voltage due to voltage drops, especially in complex environments, and existing solutions rely on additional communication cables or unreliable wireless equipment.
Innovation Solution
The system uses weld cable communications to enable power supplies and wire feeders to communicate through the same cable, allowing for resistance measurement and voltage compensation, eliminating the need for additional control cables and improving voltage accuracy by adjusting for cable resistance losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If long welding power cables are used to extend the welding location far from the power source, then the welding system can reach distant work areas, but voltage drop increases and weld voltage accuracy deteriorates
Solution Approach 1:
The system measures the actual weld voltage at the wire feeder location and feeds this information back to the power source controller. The controller then adjusts the output voltage to compensate for cable resistance, ensuring accurate weld voltage despite long cable lengths. This feedback loop resolves the contradiction by allowing long cables while maintaining voltage accuracy through active compensation.
2Measurement precision
If additional communication cables are added to enable power source and wire feeder communication, then voltage compensation accuracy improves, but system complexity and cable management burden increase
Solution Approach 1:
The welding power cable is made multi-functional by enabling it to carry both welding current and communication signals simultaneously. The wire feeder acts as a communication node that can both send voltage measurements back to the power source and receive control commands. This eliminates the need for separate communication cables while maintaining voltage compensation accuracy, resolving the contradiction between precision and complexity.
3Device complexity
If wireless communication equipment is used for voltage feedback, then system simplicity improves, but reliability deteriorates in welding environments
Solution Approach 1:
The welding power cable serves as an intermediary medium that enables reliable communication between the power source and wire feeder. By using the existing robust power cable infrastructure for both power delivery and communication, the system achieves both simplicity (no additional wireless equipment) and reliability (using the proven power cable medium that is already present in the welding environment).
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 simplifies welding systems by eliminating the need for extra cables, reduces operator travel, and ensures accurate weld voltages are maintained without additional communication cables or unreliable wireless equipment, enhancing operational efficiency and accuracy.
Implementation Method 1
measure a weld circuit resistance via communications over the weld circuit
Implementation Method 2
allowing for resistance measurement and voltage compensation
Implementation Method 3
weld cables (and, particularly, long weld cables) introduce a non-negligible voltage drop between the power source and the site of the work
Implementation Method 4
voltage compensation, eliminating the need for additional control cables and improving voltage accuracy by adjusting for cable resistance losses
Data Source
AI summary
Welding power supplies, wire feeders, and systems to measure a weld circuit resistance via communications over the weld circuit are disclosed. An example welding-type power supply includes: a power converter configured to: convert input power to output a current pulse via a weld circuit; and convert the input power to output welding-type power via the weld circuit; a voltage monitor configured to measure a power supply output voltage of the current pulse; a receiver circuit configured to receive, via the weld circuit, a communication comprising a second voltage measurement; and a controller configured to: determine a resistance of a portion of the weld circuit based on the power supply output voltage measurement, the second voltage measurement, and a weld circuit current measurement; and control the power converter to convert the input power to output the welding-type power based on a weld voltage setpoint and the impedance.