Patent Application
20150069033
The invention described herein pertains generally to an engine driven power supply. More particularly, the invention relates to an engine driver power supply for a welder incorporating a generator.
Frequently, welding is required where supply power may not be readily available. As such, the welding power supply may be an engine driven welding power supply incorporating a generator. The generator may supply power to the welder as well as to other power tools as may be needed on site. As different applications require different versions of welders and power tools, the trailer may be designed to carry one of many different types of welding power supplies.
Traditional welding-type apparatus can be broken into two basic categories. The first category receives operational power from transmission power receptacles, also known as static power. The second is portable or self-sufficient, stand alone welders having internal combustion engines, also known as rotating power. While in many settings conventional static power driven welders are preferred, engine driven welders enable welding-type processes where static power is not available. Rotating power driven welders operate by utilizing power generated from engine operation. As such, engine driven welders and welding-type apparatus allow portability and thus fill an important need.
Static powered welders initiate the weld process by way of a trigger on a hand-held torch or with an electrically charged stick connected to a charged electrode.
Rotating power driven welders operate similarly, as long as the engine is running. If the engine is shut down, there is typically no residual power to create an arc. To once again weld, the engine must be started and run at operational speed to produce the arc. Therefore, it is simply not possible to manually start and stop the engine between each and every break in the welding process. Further, even during longer periods, operators may find it easier to let the engine run because of distance to the engine, a misconception that it is better for the engine, or just out of habit.
In accordance with the present invention, there is provided a hybrid power supply for a welder including a controller; an energy storage device electrically connected to the controller to provide power to the controller; an engine having a drive shaft, the engine including a generator adapted to provide power to the controller; a power take off including a transmission having a first portion coupled to the drive shaft and a second portion attachable to an external device; and wherein the controller is adapted to supply power to an implement for a welding operation, the controller regulating the power output from the energy storage device and the engine based on the power required by the implement and the external device.
In accordance with the present invention, there is provided a welding device that includes at least the following: a motor-driven welder assembly including an engine that is a power source for the welding device to perform a welding operation; an energy storage device that provides a supplemental power source to the power source to perform the welding operation; a switch component that is configured to automatically switch between the engine and the energy storage device to perform the welding operation based on a welding parameter; the engine having a drive shaft, the engine including a generator adapted to provide power to a controller; a power take off including a power transmission having a first portion coupled to the drive shaft and a second portion attachable to an external device; wherein the controller is adapted to supply power to an implement for a welding operation, the controller regulating the power output from the energy storage device and the engine based on the power required by the implement and the external device; and a gear box that selectively transmits rotational power from the engine to the external device based upon at least one of a signal from the controller or a user input, wherein the gear box includes at least one set of gears that transmit rotation from the drive shaft of the engine to an angle relative to an axis of the drive shaft.
In accordance with the present invention, there is provided a welding device that includes at least the following: a motor-driven welder assembly including an engine that is a power source for the welding device to perform a welding operation; an energy storage device that provides a supplemental power source to the power source to perform the welding operation; a switch component that is configured to automatically switch between the engine and the energy storage device to perform the welding operation based on a welding parameter; the engine having a drive shaft, the engine including a generator adapted to provide power to a controller; a power take off including a power transmission having a first portion coupled to the drive shaft and a second portion attachable to an external device; wherein the controller is adapted to supply power to an implement for a welding operation, the controller regulating the power output from the energy storage device and the engine based on the power required by the implement and the external device; a gear box that selectively transmits rotational power from the engine to the external device based upon at least one of a signal from the controller or a user input, wherein the gear box includes at least one set of gears that transmit rotation from the drive shaft of the engine to an angle relative to an axis of the drive shaft; and the controller utilizing a dynamically defined threshold that is determined based on a portion of historic data related to one or more welding operations, wherein the historic data includes a detected fault during the one or more welding operations, wherein the dynamically defined threshold is one of a voltage generated by the generator or the energy storage device, a current generated by the generator or the energy storage device, a voltage consumed by the welding operation, a voltage consumed by the external device, a current consumed by the welding operation, and a current consumed by the external device
These and other objects of this invention will be evident when viewed in light of the drawings, detailed description and appended claims.
The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
The following description and the annexed drawings set forth in detail certain illustrative aspects of the claimed subject matter. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation may be employed and the claimed subject matter is intended to include all such aspects and their equivalents. Other advantages and novel features of the claimed subject matter will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.
Embodiments of the invention relate to an engine driven power supply. The power supply in the example shown provides power suitable for a welding operation including but not limited to arc welding, gouging, plasma cutting, heating, and the like. It will be appreciated that the power supply of the invention may be used in other power supply applications including portable power generation, backup power generation. Reference to the engine driven power supply being used as an engine driven welder or in connection with a welding operation, herein, should not be considered limiting.
The subject innovation can be used with any suitable engine-driven welder, engine-driven welding system, engine-driven welding apparatus, a welding system powered by an engine, a welding system powered by a battery, a welding system powered by an energy storage device, a hybrid welder (e.g., a welding device that includes an engine driven power source and an energy storage device or batter), or a combination thereof. It is to be appreciated that any suitable system, device, or apparatus that can perform a welding operation can be used with the subject innovation and such can be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. The engine driven welder can include a power source that can be used in a variety of applications where outlet power is not available or when outlet power will not be relied on as the sole source of power including portable power generation, backup power generation, heating, plasma cutting, welding, and gouging. The example discussed herein relates to welding operations, such as, arc welding, plasma cutting, and gouging operations. It is to be appreciated that a power source can generate a portion of power, wherein the portion of power is electrical power. It is to be appreciated that “power source” as used herein can be a motor, an engine, a generator, an energy storage device, a battery, a component that creates electrical power, a component that converts electrical power, or a combination thereof. It is to be appreciated that a switch component can be configured to automatically switch between the engine (or generator) and the energy storage device to supply power to perform the welding operation. By way of example and not limitation,
The disclosed power supply of the invention may be used in connection with an engine-driven welder, engine-driven welding system, engine-driven welding apparatus, a welding system powered by an engine alone or in combination with an energy storage device i.e. a hybrid welding power supply. It is to be appreciated that any suitable system, device, or apparatus that can perform a welding operation can be used with the subject innovation and such can be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. The engine driven welder can include a power source that can be used in a variety of applications where outlet power is not available or when outlet power will not be relied on as the sole source of power.
By way of example and not limitation,
The housing 112 of the power supply 100 also houses an internal combustion engine. To accommodate engine, housing 112 may include an exhaust port 130 and a fuel port 132 that protrude through the housing 112. The exhaust port 130 extends above the top panel 122 of the housing 112 and directs exhaust emissions away from the power supply 100. The fuel port 132 preferably does not extend beyond the top panel 122 or side panel 124. Such a construction protects the fuel port 132 from damage during transportation and operation of the power supply 100. In embodiment, the power supply 100 can be an engine-driven welder, an energy storage device driven welder, a hybrid welding device, or a combination thereof.
Referring now to
The welding arc or cutting arc is generated by the power source by conditioning raw power received from an engine 225 and an energy storage device 226. In a preferred embodiment, energy storage device 226 includes one or more batteries. Energy storage device 226 is interchangeable with similarly configured batteries. Specifically, energy storage device 250 is encased in a housing 260. Housing 260 is securable to the housing of welding device 210 thereby forming welding-type apparatus 205. Specifically, energy storage device 250 is secured to power source 210 by way of a fastener 261. It is contemplated that fastener 261 may include a clip, locking tab, screw, bolt, or other means to allow energy storage device 250 to be repeatedly secured and released from power source 210.
The engine 425 and energy storage device 450 may be operated individually or in tandem to provide electricity for the welding operation and any auxiliary operations performed by hybrid welder 400. For example, individual operation may include operating the engine 425 and supplementing the power from the engine 425 with power from the energy storage device 450 on an as needed basis. Or supplying power from the energy storage device 450 alone when the engine 425 is offline. Tandem operation may also include combining power from engine 425 and energy storage device 450 to obtain a desired power output. According to one aspect of the invention, a welder 400 may be provided with a motor having less power output than ordinarily needed, and energy storage device 450 used to supplement the power output to raise it to the desired power output level. In an embodiment, an engine with no more than 19 kW (25 hp) output may be selected and supplemented with six 12 volt batteries. Other combinations of engine output may be used and supplemented with more or less power from energy storage device. The above example, therefore, is not limiting.
Energy storage device 450 may be any alternative power source including a secondary generator, kinetic energy recovery system, or, as shown, one or more batteries 451. In an embodiment, six 12 volt batteries 451 are wired in series to provide power in connection with engine-driven welder assembly 420. Batteries 451 shown are lead acid batteries. Other types of batteries may be used including but not limited to NiCd, molten salt, NiZn, NiMH, Li-ion, gel, dry cell, absorbed glass mat, and the like.
The best mode for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time of the filing of this patent application. The examples and figures are illustrative only and not meant to limit the invention, which is measured by the scope and spirit of the claims. Referring now to the drawings, wherein the showings are for the purpose of illustrating an exemplary embodiment of the invention only and not for the purpose of limiting same,
With reference to
In the embodiment shown in
In the example shown in
According to another aspect of the invention, controller C manages the power delivery from power source 400 when the power take off 475 is in use. For example, in a hybrid configuration, where an engine 425 and energy storage device 450 may both provide power for the welding operation, controller C can alter the amount of power drawn from energy storage device 450 to make up for the draw of power by the power take off 475 on the engine 425. Controller C may supplement the power from engine 425 with power from energy storage device 450 to make up for any deficiency created by the draw of power take off on engine, or to allow the engine 425 to work at a lower level while maintaining the desired power output to implement I for the welding operation. Extrapolating this, the controller C may draw all of the power necessary for the welding operation from an energy storage device 450 when the power take off 475 is engaged to allow the engine 425 to solely supply power to the power take off 475. Alternatively, when engine 425 is running but no welding operation is underway, controller C may use the power produced by engine 425 to recharge energy storage device 450 or engine 425 may be used solely to power the power take off 475 and the associated external device 500. It will be understood that reference to an external device 500 is not limiting in terms of how the device 500 is mounted or configured with respect to hybrid welder 400. Device 500 may be mounted internally, externally, remotely from hybrid welder 400, or a combination thereof. In an embodiment, external device 500 may be supported on hybrid welder 400.
Controller C is further configured to manage power distribution. In particular, controller C can determine to distribute power from engine 425 and/or energy storage device 450. For instance, controller C can distribute power from power sources (e.g., engine 425, energy storage device 450, or combination thereof) to perform a welding operation or to drive external device 500, wherein the distribution is based upon a parameter. For instance, controller C can, based upon a parameter, distribute power from one or more power sources (e.g., engine 425 and/or energy storage device 450) as follows: distribute power solely to perform a welding operation with via implement I; distribute power to charge energy storage device 450; distribute power to both perform a welding operation and charge energy storage device 450; distribute power solely to external device 500; distribute power to perform a welding operation, charge energy storage device 450, and distribute power to external device 500; or a combination thereof.
Controller C can distribute power from a power source (e.g., energy storage device 450, engine 425, or a combination thereof) to at least one of powering an external device 500, performing a welding operation, or charging energy storage device 450. The following are examples of the parameter that can be evaluated by controller C to identify how to distribute power generated and to where such power should be utilized for consumption.
In an embodiment, the parameter can be a welding parameter. For instance, the welding parameter can be, but is not limited to, a voltage of the welding operation, a current of the welding operation, a welding schedule parameter (e.g., welding process, wire type, wire size, wire feed speed (WFS), volts, trim, a wire feeder to use, feed head to use, among others), a position of a welding tool, a composition of the workpiece on which the welding operation is performed, a position or location of an operator, sensor data (e.g., video camera, image capture, thermal imaging device, heat sensing camera, temperature sensor, among others), a portion of a waveform used for the welding operation, a location on a waveform during progression through a welding operation, a wire feed speed, a type of weld, a workpiece composition, and the like.
In an embodiment, the parameter can be related to a power source (e.g., engine 425, energy storage device 450, or a combination thereof) such as, but not limited to, an amount of fuel available for engine 425, a cost of a fuel for engine 425, a fuel consumption efficiency for engine 425, a duration of time the engine 425 operates, an amount of charge stored in energy storage device 450, a signal from controller C of the welding operation, a signal from a controller associated with implement I, and the like. For instance, a signal from implement I can be from a input device that allows a user to select a manner in which to distribute power. The input device can be, but is not limited to being, a button, a switch, a toggle switch, a knob, an analog knob, a touchpad, a touch screen, a mouse, a mouse button, a keyboard, a keypad, a microphone, a camera, a video camera, a motion sensor, and the like. In general, input device can receive an input from a user or an operator to control power distribution. For instance, the input can be, but is not limited to being, a button activation, a switch activation, a voice command, a motion, a gesture, a hand gesture, an eye movement, a sound, a touch screen input, and the like. In another embodiment, input device is a stand-alone device, incorporated into hybrid welder 400, incorporated into external device 500, or a combination thereof.
In an embodiment, the parameter can be related to external device 500. The parameter can be, but is not limited to being, a type of external device 500, a rating of electrical demand of external device 500 (e.g., needed voltage for operation, needed current for operation, etc.), among others. In an embodiment, the parameter can be a condition external to hybrid welder 400 such as, but not limited to, a geographic location, a temperature, a barometer reading, a humidity level, a weather condition, an altitude, a wind speed, an amount of cloud cover, an weather forecast, an amount of precipitation, and the like.
In another embodiment, controller C can include one or more thresholds to manage distribution of power. For instance, a threshold can be user defined or dynamically defined based on historic data. In an example, a user defined threshold can be set for a power consumption of the external device 500 that upon being reached (e.g., exceeded, met, or fall below), can distribute power to the external device 500 or cease power distribution to the external device 500. In another example, a user defined threshold can be set for an amount of power to be used for a welding operation and that when such threshold is reached, power is to be distributed to perform the welding operation or to cease distribution of power to perform the welding operation. In still another example, a user defined threshold can be set for either the power to perform the welding operation or the power consumption of the external device 500 and upon such threshold being reached a power can be distributed to charge energy storage device 450.
In another embodiment, the welding operation and use of external device 500 can be monitored and one or more thresholds can be dynamically identified and set. For instance, based on a power consumption of the external device 500 or a welding operation, the power needed for the welding operation or the external device 500 may not be met and a fault can occur. The fault can be automatically detected based on a predefined default threshold or based on a user input (e.g., user input identifying a fault occurred due to power distribution). Such fault can be recorded and one or more parameters (e.g., power setting, external device 500 power consumption, engine 425 setting, energy storage device 450 setting, voltage generated by power source, current generated by power source, voltage consumed by welding operation, voltage consumed by external device, current consumed by welding operation, current consumed by external device, and the like) are utilized to set a threshold for a subsequent welding operation. Such evaluated parameter(s) can be used as a threshold (replacing the predefined default threshold) for controlling a power distribution.
In an embodiment, the power transmission is at least one of a bolted joint, splined shaft and receiver, gear box, or clutch. In an embodiment, the subject innovation can further include a gear box that selectively transmits rotational power from the engine to the external device based upon at least one of a signal from the controller or a user input. In an embodiment, the gear box includes at least one set of gears that transmit rotation from the drive shaft of the engine to an angle relative to an axis of the drive shaft. In an embodiment, the angle is 90 degrees.
In an embodiment, the subject innovation can further include the controller distributing power from at least one of the generator or the energy storage device to perform a welding operation or to drive the external device. In an embodiment, the controller distributing power is based upon a welding parameter. In an embodiment, the welding parameter is at least one of a voltage of the welding operation, a current of the welding operation, a wire feed speed, a type of weld, or a workpiece composition. In an embodiment, the welding parameter is at least one of a welding schedule parameter, welding process, wire type, wire size, wire feed speed (WFS), volts, trim, a wire feeder to use, or feed head to use. In an embodiment, the welding parameter is at least one of a position of a welding tool, a composition of the workpiece on which the welding operation is performed, a position or location of an operator, or a portion of sensor data. In an embodiment, the welding parameter is at least one of a portion of a waveform used for the welding operation, or a location on a waveform during progression through a welding operation.
In an embodiment, the subject innovation can further include the controller distributing power from at least one of the generator or the energy storage device to perform a welding operation or to drive the external device based on at least one of an amount of fuel available for engine, a cost of a fuel for engine, a fuel consumption efficiency for engine, a duration of time the engine operates, an amount of charge stored in energy storage device, or a signal from the controller. In an embodiment, the subject innovation can further include the controller distributes power from at least one of the generator or the energy storage device with at least one of the following: distribution of power solely to perform a welding operation; distribution of power to charge the energy storage device; distribution of power to perform a welding operation and charge the energy storage device; distribution of power solely to the external device; or distribution of power to perform a welding operation, charge the energy storage device, and distribute power to the external device. In an embodiment, the external device is at least one of a hydraulic pump, a blower, a fume evacuation system, a winch, a generator, a compressor, or an implement.
In an embodiment, the welding parameter is at least one of a voltage of the welding operation, a current of the welding operation, a wire feed speed, a type of weld, a workpiece composition, a portion of a waveform used for the welding operation, or a location on a waveform during progression through a welding operation. In an embodiment, the external device is at least one of a hydraulic pump, a blower, a fume evacuation system, a winch, a generator, a compressor, or an implement.
In an embodiment, the subject innovation can further include the controller utilizing a dynamically defined threshold that is determined based on a portion of historic data related to one or more welding operations, wherein the historic data includes a detected fault during the one or more welding operations.
In an embodiment, the controller utilizes at least one of the following as the dynamically defined threshold based on the detected fault: a power setting; a power consumption of the external device; a setting of the engine; a setting of the energy storage device; a voltage generated by the generator or the energy storage device; a current generated by the generator or the energy storage device; a voltage consumed by the welding operation; a voltage consumed by the external device; a current consumed by the welding operation; or a current consumed by the external device.
The above examples are merely illustrative of several possible embodiments of various aspects of the present invention, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, circuits, and the like), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component, such as hardware, software, or combinations thereof, which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the invention. In addition although a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in the detailed description and/or in the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”
This written description uses examples to disclose the invention, including the best mode, and also to enable one of ordinary skill in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
The best mode for carrying out the invention has been described for purposes of illustrating the best mode known to the applicant at the time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and merit of the claims. The invention has been described with reference to preferred and alternate embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
This application claims the benefit of priority to U.S. Provisional Application Ser. No. 61/876,865, filed Sep. 12, 2013, and entitled “ENGINE DRIVEN POWER SUPPLY.” The entirety of the aforementioned application is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61876865 | Sep 2013 | US |
