Patent Application
20250144732
The subject disclosure relates to a welding power source capable of delivering both DC and AC weld power for welding operations, in particular a welding power source having circuitry for bypassing components of an AC power stage during DC welding operations.
Welding power sources typically generate output weld power for a welding or cutting process by converting input alternating-current (AC) power from AC mains or a generator to direct-current (DC) power, and then converting the DC power to output power suitable for the welding or cutting process via a weld process regulator. The output power required for many welding operations is DC power. AC weld power can also be used in certain types of welding operations such as, for example, in tungsten inert gas (TIG) welding, where the electric welding arc is formed between a non-consumable tungsten electrode and the workpiece. While DC power may be preferable in some TIG welding operations, such as when welding certain types of steel, AC TIG weld power is more typically used to weld aluminum. Further, manual ignition of the welding arc, e.g., via a “scratch start,” is difficult to achieve in TIG welding. More advance welding power sources often include circuitry to generate high-frequency (HF) AC power that can be used to initiate the welding arc in TIG welding without touching the electrode to the workpiece, thereby significantly simplifying arc ignition. However, inclusion of circuitry to generate AC power for TIG operations can potentially introduce power losses that impact the power efficiency of the welding power source during DC welding operations.
A welding power source comprises a DC-AC selector stage configurable to supply either DC weld power or AC weld power to output power terminals of the welding power source. The DC-AC selector stage comprises a first switch element including a first switch and a first relay arranged in parallel, and a second switch element including a second switch and a second relay arranged in parallel. A weld controller controls the first and second switches and the first and second relays to select a DC power mode in which the DC weld power passes through the DC-AC selector stage to the output power terminals and to select an AC power mode in which DC weld power is converted to AC weld power and supplied to the output power terminals.
An example welding system 100 suitable for implementing the techniques and circuitry described herein is shown in the high-level functional block diagram of
In this example, because welding system 100 includes a wire electrode feeder 106 and a gas supply 112, the system is capable of performing Gas Metal Arc Welding (GMAW), such as Metal Inert Gas (MIG) and Metal Active Gas (MAG) welding in at least some modes of operation. In general, welding system 100 can have any suitable configuration for performing a variety of different types of welding operations. As used herein the terms “weld” and “welding” refer to any of a wide range of arc welding and plasma cutting systems including but not limited to GMAW (MIG/MAG) welding, tungsten inert gas (TIG) welding, flux cored arc welding (FCAW), shielded metal arc welding (SMAW), also known as Manual Metal Arc (MMA) welding or “stick” welding, and submerged arc welding (SAW) systems. In the context of arc welding, torch 110 may be referred to as a “welding torch” or “welding gun.” In the context of plasma cutting, torch 110 may be referred to as a “cutting torch.” Thus, as used herein, the term “torch” means either a welding torch (or welding gun) or a cutting torch, depending on context. In the case of TIG welding, the electrode is not a consumable wire, and a wire electrode feeder is not required. In the case of MMA welding, neither the wire electrode feeder nor a gas supply for providing shielding gas is required. In at least one mode of operation, welding power source 102 is designed to deliver DC power to a welding operation, and in at least one mode of operation, welding power source 102 is designed to deliver AC power to a welding operation.
Wire electrode feeder 106 includes a feeder 116 to feed a consumable electrode from a coiled wire electrode 120 through cable assembly 108 and through contact tip 111 of torch 110, which is in electrical contact with the electrode. Welding power source 102 generates weld power at “positive” and “negative” terminals 130a, 103b (e.g., on a front panel or other external panel of welding power source 102) that drives the welding (or cutting) process/operation. In the case of MIG/MAG welding operations, welding power source 102 provides the weld power from positive terminal 130a to the wire electrode, through feeder 116, cable assembly 108, and torch 110, while the cable assembly 108 also delivers a shielding gas from gas supply 112 to the torch. In the case of TIG or MMA welding, welding power source 102 may supply power from positive terminal 130a to the torch 110 (without a wire electrode feeder), and shielding gas is not required for MMA welding. Return path/cable 115 provides an electrical return path from workpiece 114 to negative terminal 130b of welding power source 102. The aforementioned components comprise a circuit path or weld circuit from positive terminal 130a to negative terminal 130b of welding power source 102, through wire electrode feeder 106 (in the case of GMAW), cable assembly 108, torch 110, workpiece 114, and return path/cable 115.
During a welding operation, an electrode tip 118 of the electrode is brought into contact or near contact with workpiece 114, and the weld power supplied by welding power source 102 to the torch 110 creates an arc between workpiece 114 and electrode tip 118 (also referred to as an “electrode stick”) extending through the contact tip 111. To control the welding process, welding power source 102 generates the weld power (e.g., current) at a desired level for the welding process, based on the weld process setting and feedback in the form of measurements of the current and voltage (e.g., arc voltage). The measurements may be produced by current and voltage sense points in welding power source 102 and/or at sense points that are remote from welding power source 102, such as in cable assembly 108 or torch 110.
In particular, inverter 204 comprises a set of high-speed semiconductor switching devices (i.e., power switches) that are pulse width modulated (i.e., switched on and off at a switching frequency) responsive to pulse width modulation (PWM) signals generated by weld controller 208 and applied to control terminals of the switching devices to convert the DC bus voltage to an AC (power) signal or waveform including a voltage and a primary current IL, that flows into HF transformer 206. Such operation is referred to as “PWM operation” of inverter 204. Inverter 204 may include a four-quadrant inverter, such as an H-bridge inverter, for example. In other examples, other types of inverters may be employed. Example switching frequencies may be in a range from 1 kHz-100 kHz, although other switching frequencies above and below this range may be used, and for the inverter and the transformer, the term “high-frequency” encompasses this frequency range. Inverter 204 supplies the AC signal to HF transformer 206. HF transformer 206 transforms the voltage and current characteristics of the AC signal from inverter 204 to a transformed AC signal having desired levels of a voltage and a secondary current Is for the welding operation, and supplies the transformed AC signal to secondary rectifier 210. For example, the power upstream of HF transformer 206 (on the primary side) has a relative high voltage and low current, and the power downstream of HF transformer 206 (on the secondary side) has a relatively low voltage and high current. According to one non-limiting example, the primary-to-secondary winding ratio (N1:N2,N3) of HF transformer 206 can be 18:4,4. Secondary rectifier 210 rectifies the transformed AC signal to produce DC weld power and, for DC welding operations, supplies the same to the weld output to downstream welding or plasma cutting equipment (e.g., a wire feeder, a welding gun or torch, a plasma torch, etc.).
The welding power source of
The example welding power source of
AC weld power is useful for welding aluminum and magnesium, e.g., with AC TIG welding, which takes advantage of the positive voltage, and hence primary heating location, rapidly fluctuating between the electrode and the workpiece. DC weld power typically experiences a significant voltage drop where longer power cables are required between the welding power source and the welding torch. AC weld power is less susceptible to such voltage drops over long cables; thus, both TIG and MMA (stick) welding operations can benefit from AC welding power when longer power cables are required. AC weld power may also create a more stable arc when welding metals prone to magnetic fields by preventing arc blow and arc deflection.
More specifically, switch element Q1 comprises two IGBTs and a diode, all arranged in parallel with each other. The collectors of the two IGBTs are connected to the rectified output of secondary rectifier 210 on the first voltage line, and the emitters of the two IGBTs are connected to the positive weld output terminal, e.g., on the front panel of the welding power source. The positive terminal of the diode of switch element Q1 is connected to the collectors of the two IGBTs at the first voltage line, and the negative terminal of the diode is connected to the emitters of the two IGBTs at the positive weld output terminal.
Switch element Q2 likewise comprises two IGBTs and a diode, all arranged in parallel with each other. The collectors of the two IGBTs and the positive terminal of the diode of the switch element Q2 are connected to the negative weld output terminal, e.g., on the front panel of the welding power source. The emitters of the two IGBTs and the negative terminal of the diode of switch element Q2 are connected to the center tap of the secondary output of HF transformer 206 via an inductor on the second voltage line.
Switch element Q3 comprises an IGBT arranged in parallel with a diode. The collector of the IGBT and the positive terminal of the diode of switch element Q3 are connected to the rectified output of the secondary rectifier on the first voltage line, and the emitter of the IGBT and the negative terminal of the diode of switch element Q3 are connected to the negative weld output terminal. Switch element Q4 comprises an IGBT arranged in parallel with a diode. The collector of the IGBT and the positive terminal of the diode of switch element Q4 are connected to the positive weld output terminal, and the emitter of the IGBT and the negative terminal of the diode of switch element Q4 are connected to the center tap of the secondary output of HF transformer 206 via the inductor on the second voltage line.
Since switch elements Q1 and Q2 are continuously on during DC operations to pass the DC power signal from secondary rectifier 210 to the weld output, switch element Q1 and Q2 each have two IGBTs arranged in parallel to handle the higher DC currents that flow through switch element Q1 and Q2. In contrast, switch elements Q3 and Q4 are maintained in an off state during DC operations and consequently require only a single IGBT to handle current flow during AC operation. In the arrangement shown in
Like the DC-AC selector stage 300 shown in
More specifically, switch element Q1 comprises an IGBT, a diode, and a high-current relay RL1 all arranged in parallel with each other. The collector of the IGBT, the positive terminal of the diode, and one end of the relay RL1 of switch element Q1 are connected to the rectified output of the secondary rectifier on the first voltage line. The emitter of the IGBT, the negative terminal of the diode, and the other end of the relay RL1 are connected to the positive terminal of the weld output on the output panel of the welding power source.
Switch element Q2 likewise comprises an IGBT, a diode, and a high-current relay RL2 all arranged in parallel with each other. The collector of the IGBT, the positive terminal of the diode, and one end of the relay RL2 of switch element Q2 are connected to the negative weld output terminal, e.g., on the front panel of the welding power source. The emitter of the IGBT, the negative terminal of the diode, and the other end of the relay RL2 of switch element Q2 are connected to the center tap of the HF transformer 206 secondary output via an inductor on the second voltage line.
Switch element Q3 comprises an IGBT arranged in parallel with a diode. The collector of the IGBT and the positive terminal of the diode of switch element Q3 are connected to the rectified output of secondary rectifier 210 on the first voltage line, and the emitter of the IGBT and the negative terminal of the diode of switch element Q3 are connected to the negative weld output terminal. Switch element Q4 comprises an IGBT arranged in parallel with a diode. The collector of the IGBT and the positive terminal of the diode of switch element Q4 are connected to the positive weld output terminal, and the emitter of the IGBT and the negative terminal of the diode of switch element Q4 are connected to the center tap of the secondary output of HF transformer 206 via the second voltage line.
During DC operations such as for MIG/MAG, DC MMA, DC TIG, etc., weld controller 208 keeps the switches (e.g., IGBTs) of switch elements Q1 and Q2 continuously in an on state (passing current) and keeps the relays RL1 and RL2 continuously on (closed), while keeping the switches of switch elements Q3 and Q4 continuously in an off state (open circuit). This configuration allows DC power from the secondary rectifier to pass through the DC-AC selector stage 400 to the weld output with a reduced power loss. Specifically, because relays RL1 and RL2 have a lower resistance than the IGBTs, the parallel arrangement of the relays and IGBTs causes the majority of the current to flow through the relays and only a small fraction of the current to flow through the IGBTs. Thus, most of the DC weld current is rerouted through the relays and largely bypasses the IGBTs of switch elements Q1 and Q2, thereby reducing the conduction losses of the IGBTs. This arrangement not only eliminates the need for the second IGBT in each of the switches Q1 and Q2 to handle the high DC current, but also reduces the power loss by an order of magnitude (e.g., approximately one-tenth of the power loss) relative to the implementation shown in
During AG power operation of DC-AC selector stage 400 shown in
At 502, weld controller 208 controls DC-AC selector stage 400 to selects the AC power mode by controlling the first, second, third, and fourth switches of DC-AC selector stage 400, which are arranged in an H-bridge configuration, to convert the input DC weld power from the secondary rectifier to AC weld power. Specifically, by switching the switches on and off, the H-bridge switch arrangement operates as a full-bridge inverter to produce the AC weld power at the switching frequency, as previously described. During the AC power mode, the first and second relays of DC-AC selector stage 400 are kept continuously in an open state (open circuit) to prevent current from flowing through the relays. The AC weld power at the output power terminals of the welding power source during the AC power mode can be supplied to a welding torch operating in an AC power mode, such as a TIG welding torch or an MMA welding torch.
At 504, weld controller 208 controls DC-AC selector stage 400 to select the DC power mode by closing the first and second relays of DC-AC selector stage 400, thereby bypassing the first and second switches, respectively. Weld controller 208 also keeps the third and fourth switches of DC-AC selector stage 400 in an off state, such that the input DC weld power flows from the input to the output of DC-AC selector stage 400 via the first and second relays. Weld controller 208 can also keep the first and second switches of DC-AC selector stage 400, which are in parallel with the first and second relays, respectively, in an on state during the DC power mode, such that some portion of the input DC weld power can flow through the first and second switches in parallel with the first and second relays. The DC weld power at the output power terminals of the welding power source during the DC power mode can be supplied to a welding torch operating in a DC power mode, such as a MIG/MAG welding torch, a TIG welding torch, or an MMA welding torch.
In some aspects, the techniques described herein relate to a welding power source comprising: a primary rectifier to converter alternating-current (AC) input power to direct-current (DC) power; an inverter to convert the DC power to an AC signal; a transformer to transform the AC signal to a transformed AC signal having different voltage and current characteristics than the AC signal; a secondary rectifier to rectify the transformed AC signal to generate DC weld power; a DC-AC selector stage to receive the DC weld power and configurable in a DC power mode and in an AC power mode, the DC-AC selector stage comprising a first switch element including a first switch and a first relay arranged in parallel and a second switch element including a second switch and a second relay arranged in parallel; and a weld controller to control the first and second switches and the first and second relays to select the DC power mode in which the DC weld power passes through the DC-AC selector stage to first and second output power terminals of the welding power source and to select the AC power mode in which the DC weld power is converted to AC weld power by the DC-AC selector stage and supplied to the first and second output power terminals.
In some aspects, the techniques described herein relate to a welding power source wherein, during the DC power mode, the weld controller is operable to keep the first and second relays closed to bypass the first and second switches and, during the AC power mode, the weld controller is operable to keep the first and second relays open.
In some aspects, the techniques described herein relate to a welding power source wherein, during the DC power mode, the weld controller is operable to keep the first and second switches on and, during the AC power mode, the controller is operable to switch the first and second switches on and off to convert the DC weld power to the AC weld power.
In some aspects, the techniques described herein relate to a welding power source wherein: the transformer has on its secondary side first and second end taps and a center tap; the secondary rectifier receives transformer output signals from the first and second end taps and supplies the DC weld power to the DC-AC selector stage on a first voltage line; and the DC-AC selector stage is connected to the center tap of the transformer via a second voltage line.
In some aspects, the techniques described herein relate to a welding power source wherein: the first relay and the first switch are between the first voltage line and the first output power terminal; and the second relay and the second switch are between the second voltage line and the second output power terminal.
In some aspects, the techniques described herein relate to a welding power source wherein: the DC-AC selector stage further comprises a third switch element including a third switch and a fourth switch element comprising a fourth switch; the third switch is between the first voltage line and the second output power terminal; and the fourth switch is between the second voltage line and the first output power terminal.
In some aspects, the techniques described herein relate to a welding power source wherein: during the DC power mode, the weld controller is operable to keep the first and second relays closed and the third and fourth switches in an off state; and during the AC power mode, the controller is operable to keep the first and second relays open and to switch the first, second, third, and fourth switches on and off to convert the DC weld power to AC weld power.
In some aspects, the techniques described herein relate to a welding power source wherein, during the DC power mode, the weld controller is operable to keep the first and second switches in an on state.
In some aspects, the techniques described herein relate to a welding power source wherein the DC-AC selector stage further comprises a third switch element including a third switch and a fourth switch element comprising a fourth switch, the first, second, third, and fourth switch elements being arranged as an H-bridge.
In some aspects, the techniques described herein relate to a welding power source wherein the weld controller is operable to control the DC-AC selector stage as a full-bridge inverter during the AC power mode.
In some aspects, the techniques described herein relate to a welding power source wherein the first switch element further comprises a first diode arranged in parallel with the first switch and the first relay, and the second switch element further comprises a second diode arranged in parallel with the second switch and the second relay.
In some aspects, the techniques described herein relate to a welding power source wherein the first and second switches comprise insulated-gate bipolar transistor (IGBT) switches.
In some aspects, the techniques described herein relate to a welding power source wherein the first switch is a sole switch of the first switch element, and the second switch is a sole switch of the second switch element.
In some aspects, the techniques described herein relate to a welding power source wherein the secondary rectifier is a full-bridge rectifier comprising four diodes.
In some aspects, the techniques described herein relate to a welding system comprising: the aforementioned welding power source; a cable assembly; and a TIG welding torch to receive weld power from the welding power source via the cable assembly, wherein: the welding system is operable in a DC TIG welding mode in which the welding power source supplies the DC weld power to the TIG welding torch, and the welding system is operable in an AC TIG welding mode in which the welding power source supplies the AC weld power to the TIG welding torch.
In some aspects, the techniques described herein relate to a DC-AC selector stage for a welding power source, comprising: a first switch element comprising a first relay and a first switch arranged in parallel between an output of a secondary rectifier downstream of a transformer and a first output power terminal of the welding power source; a second switch element comprising a second relay and a second switch arranged in parallel between a center tap of the transformer and a second output power terminal of the welding power source; a third switch element comprising a third switch between the output of the secondary rectifier and the second output power terminal; and a fourth switch clement comprising a fourth switch between the center tap of the transformer and the first output power terminal, wherein: the DC-AC selector stage is operable in an AC power mode in which the first and second relays are in an open state and the first, second, third, and fourth switches are operated as an H-bridge inverter to convert DC power to AC weld power; and the DC-AC selector stage is operable in a DC power mode in which the first and second relays are in a closed state and the third and fourth switches are in an off state to pass DC weld power to the first and second weld output terminals of the welding power source.
In some aspects, the techniques described herein relate to a DC-AC selector stage, wherein the first, second, third, and fourth switch elements are operable as a full-bridge inverter in the AC power mode.
In some aspects, the techniques described herein relate to a method of controlling a welding power source, comprising: selecting an AC power mode by controlling first, second, third, and fourth switches arranged in an H-bridge configuration to convert DC weld power to AC weld power; and selecting a DC power mode by closing first and second relays that respectively bypass the first and second switches and by keeping the third and fourth switches in an off state.
In some aspects, the techniques described herein relate to a method wherein selecting the DC power mode further includes keeping the first and second switches in an on state.
In some aspects, the techniques described herein relate to a method further comprising: supplying the AC weld power to a TIG welding torch during the AC power mode; and supplying the DC weld power to the TIG welding torch during the DC power mode.
The descriptions of the various implementations have been presented for purposes of illustration but are not intended to be exhaustive or limited to the implementations disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described implementations. The terminology used herein was chosen to best explain the principles of the implementations, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the implementations disclosed herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202241029505 | May 2022 | IN | national |
This application is a continuation of International (PCT) Patent Application No. PCT/IB2023/055307, filed May 23, 2023, and entitled “AC Power Stage Bypass in a Welding Power Source,” which claims priority to and is based on Indian Provisional Patent Application No. 20/224,1029505, filed on May 23, 2022, and entitled “AC Power Stage Bypass in a Welding Power Source.” The entire disclosure of each of these applications is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/IB2023/055307 | May 2023 | WO |
| Child | 18954957 | US |
