Patent Application
20220258269
The present disclosure relates generally to welding systems and, more particularly, to energy storage devices for welding systems.
Welding is a process that has become increasingly ubiquitous in various industries and applications. As such, a variety of welding applications, such as construction and shipbuilding, may require welding devices that are portable and can easily be transported to a remote welding location. Accordingly, in some cases, it is often desirable for such welding devices to be operable as standalone units remote from a power grid or other utility power. Therefore, a variety of welding systems utilizing alternate power sources, such as batteries, have been developed. Furthermore, during a welding operation, some weld load demands may be relatively small (e.g., below 150 amps), and to meet such small load demands, the engine-generator unit is activated. However, activation of the engine-generator to meet such small load demands is often relatively inefficient. Additionally, during some welding operations, welding devices, whether powered by a power grid or an engine-generator, may have current output limitations. Accordingly, there exists a need for energy storage systems for use with welding systems to improve overall efficiency, output, and versatility of the welding system.
In one embodiment, a welding system includes a welder configured to supply a secondary power output, and an energy storage caddy coupled to a secondary side of the welder and configured to receive the secondary power output from the welder. The energy storage caddy includes an energy storage device configured to provide a supplemental power output and control circuitry configured to synchronize operation of the welder and the energy storage caddy based on at least one operating parameter of the welding system, wherein the energy storage caddy is configured to combine the secondary power output and the supplemental power output to produce a total power output, and output the total power output to a welding operation.
In another embodiment, a method includes providing a first power output with a welder, providing a second power output with an energy storage device of an energy storage caddy coupled to a secondary side of the welder, combining the first power output and the second power output with the energy storage caddy to produce a total power output, and supplying the total power output to a welding operation.
In a further embodiment, an energy storage caddy for a welding system includes an energy storage device configured to provide a supplemental power output, power electronics configured to condition the supplemental power output after the supplemental power output is discharged from the energy storage device, and control circuitry configured to regulate operation of the energy storage device, the power electronics, and a welding power source configured to provide a secondary power output to the energy storage caddy based on measured operating parameter of the energy storage caddy or a user input selection, wherein the energy storage caddy is configured to be coupled to a secondary side of the welding power source.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Embodiments of the present disclosure are directed towards a welding system having a caddy type device with one or more energy storage devices running on a secondary connection of a welder or welding power supply. As discussed in detail below, the energy storage caddy may be used to improve efficiency, performance, and versatility of the welding system. For example, in certain embodiments, the energy storage caddy may be used to offset or add to an output power or current supplied by the welder, thereby increasing the overall power or current output of the welding system while reducing loading on a breaker of a primary power supply (e.g., a utility power supply). In embodiments having a welder with an engine-generator, the energy storage caddy may supplement and/or offset the current output of the welder thereby increasing the overall power or current output of the welding system while reducing fuel usage and/or noise produced by the welder. The energy storage caddy may enable additional improvements to the functionality of the welding system, as discussed below.
Turning now to the drawings,
The energy storage caddy may also be used to add high energy for short duration to arc star, clear shorts, or provide more peak power than the utility or engine based welder can provide on its own. For example,
In certain embodiments, the welder 12 may also be coupled to an external utility power, such as a utility 24 (e.g., a power grid). In other embodiments, the welder 12 may include an engine 26 configured to drive a generator 28 to produce secondary power. As mentioned above, the welder 12 and the energy storage caddy 14 of the welding system 10 are configured to generate and provide power for a welding operation. For example, the welder 12 and the energy storage caddy 14 may cooperatively generate and provide power for a welding operation. In other circumstances, the welder 12 and the energy storage caddy 14 may individually provide power for a welding operation. In other words, the welder 12 may generate and provide power for a welding operation without the energy storage caddy 14, and the energy storage caddy 14 may provide power (e.g., power stored within the energy storage caddy 14) without the welder 12. For example, in circumstances where the welder 12 individually provides power to a welding operation, power may be passed through the energy storage caddy 14 to the welding torch 18. While the energy storage caddy 14 is shown as a stand-alone unit of the welding system 10, in other embodiments the energy storage caddy 14 may be integrated with another component of the welding system 10. For example, the energy storage caddy 14 may be integrated with a welding wire feeder.
As shown, the welder 12 and the energy storage caddy 14 are coupled to one another. Specifically, the welder 12 and the energy storage caddy 14 are coupled together by a weld power cable 30 and a control cable 32. As will be appreciated, the weld power cable 30 is configured to transfer power from the welder 12 to the energy storage caddy 14. However, in certain embodiments, the weld power cable 30 may also be configured to transfer information and/or data between the welder and the energy storage caddy 14. The control cable 32 is configured to transfer data, control signals, and other information between the welder 12 and the energy storage caddy 14. As discussed in detail below, the energy storage caddy 14 may be configured to send control signals to regulate operation of the welder 12 based on operating conditions of the welding system 10, user input information or settings, feedback from the welder 12 and/or the energy storage caddy 14, or other parameters.
In the illustrated embodiment, the energy storage caddy 14 is positioned a distance 34 from the welder 12. For example, the welder 12 may be positioned proximate to a utility power (e.g., a utility plug outlet), and the energy storage caddy 14 may be positioned proximate a work site or other location for a welding operation. As will be appreciated, the distance 34 may impact a level of power received from the welder 12 by the energy storage caddy 14 (e.g., due to resistive losses along the length of the weld power cable 30). As discussed below, operation of the energy storage caddy 14 may be adjusted (e.g., automatically) based on the distance 34 to account for such losses. Additionally, as the energy storage caddy 14 may be configured to send control signals through the control cable 32 to regulate operation of the welder 12, an operator may not have to travel the distance 34 from the work site back to the welder 12 to adjust various operating parameters of the welder 12. As a result, the energy storage caddy 14 may improve efficiency of welding operations with the welding system 10.
Although the illustrated embodiment of the welding system 10 shows one energy storage caddy 14 coupled to the secondary side 16 of the welder 12, other embodiments of the welding system 10 may include multiple energy storage caddies 14. Additional details of the components and functions of the energy storage caddy 14 are described in further detail below.
The power supplied by the welder 12 to the energy storage caddy 14 is passed to the torch 18. As discussed below, power stored in the energy storage caddy 14 may be combined with the power supplied by the welder 12 before the combined power is supplied to the torch 18. Specifically, power stored in the energy storage 50 of the energy storage caddy 14 may be combined with the power supplied by the welder 12. In the illustrated embodiment, the energy storage 50 includes an energy storage device 56. The energy storage device 56 may be a battery, a fuel cell, a combination thereof, or any other suitable energy storage device. In the illustrated embodiment, the energy storage 50 includes one energy storage device 56, but other embodiments may include multiple energy storage devices 56. For example, multiple energy storage devices 56 may be coupled to one another in series, in parallel, or in any other suitable configuration.
The energy storage device 56 of the energy storage 50 is charged via power supplied from an external source. In the illustrated embodiment, the energy storage device 56 is charged from power supplied by the welder 12. Specifically, power supplied by the welder 12 is input into a charge inverter 58, which uses the power to charge the energy storage device 56. The charge inverter 58 is shown within the energy storage caddy 14 in the illustrated embodiment, however the charge inverter 58 may also be located external to the caddy 14. Additionally, in certain embodiments, the energy storage device 56 may also be charged directly via another external charge source 60. For example the external charge source 60 may be a power grid, another generator, or other suitable power source. As shown, power from the external charge source 60 is supplied to the charge inverter 58 for charging the external storage device 56. However, in other embodiments, power from the external charge source 60 may be supplied directly to the energy storage device 56 of the energy storage 50.
In operation, the power electronics 54 receives power from the energy storage device 56 and converts the power from the energy storage device 56 into a desired power output (e.g., a power output suitable for use in a welding operation). The power electronics 54 also receives power from the welder 12 (e.g., via weld power cable 30), and the power electronics 54 combines the power received from the energy storage device 56 with the power received from the welder 12. The power electronics 54 may include one or more circuit topologies for use depending on the voltage and/or current of the power supplied by the energy storage device 56 and/or the welder 12, the type of welding process or operation, or other operating conditions and parameters. For example, the power electronics 54 may include a buck converter 62, a boost converter 64, a buck/boost converter 66, any combination thereof, or any other suitable circuit. The power electronics 54 may convert the power received from the energy storage device 56 to be suitable for use with any of a variety of welding processes, such as shield metal arc welding, gas metal arc welding, stick welding, metal inert gas welding, tungsten inert gas welding, plasma welding, multi-process welding, induction welding, an auxiliary device, regulated metal disposition, and so forth. For example, the power electronics 54 may be configured to adjust or modify one or more properties of the power, such as voltage, amperage, waveform, phase, and so forth. As discussed below, the conversion or conditioning of the power by the power electronics 54 may be based on a selected welding process, operating conditions of the welding system 10, feedback from the energy storage caddy 14 and/or the welder 12, other user input, and so forth.
After the power from the energy storage device 56 is conditioned by the power electronics 54, the power electronics 54 combines the power from the energy storage device 56 with the power supplied from the welder 12. Thereafter, the combined power is directed to the torch 18 for use in a welding process or operation. As will be appreciated, the combination of the power supplied by the welder 12 with the power stored in the energy storage device 56 enables an increase in the total power that may be used in the welding system 10. That is, the utilization of the energy storage caddy 14 coupled to the secondary side 16 of the welder 12 enables an increase in total power output available to an operator during a welding process. As a result, loading on a circuit breaker of the utility 24 and or the welder 12 (e.g., loading on the utility power) may be reduced, thereby avoiding tripping of the circuit breaker and interruption of the welding operation. The supplemental power provided by the energy storage caddy 14 may also reduce noise pollution and fuel usage for the welder 12 having the engine 26 and generator 28. As discussed below, the energy storage caddy 14 may also enable more streamlined operation of the welding system 10.
As mentioned above, the energy storage caddy 14 includes control circuitry 52. The control circuitry 52 is configured to regulate operation of one or more components of the energy storage caddy 14. As such, the control circuitry 52 may communicate with one or more components of the energy storage caddy 14 (e.g., the power electronics 54), as well as with other components of the welding system 10 (e.g., the welder 12). For example, the control circuitry 52 may communicate with the welder 12 via the control cable 32. In other embodiments, the control circuitry 52 may communicate with the welder 12 via a wireless connection. The control circuitry 52 may also be configured to communicate with other components of other systems via a network connection, such as a local area network connection or an internet connection. In certain embodiments, the control circuitry 52 may also be configured to regulate operation of the welder 12 or other components of the welding system 10.
The control circuitry 52 includes a user interface 70 that enables user input of information. In the illustrated embodiment, the user interface 70 includes a display 72 and a variety of input controls 74 (e.g., switches, knobs, etc.). The user interface 70 may be used by an operator to control, adjust, and/or select a variety of operating parameters and/or conditions of the welding system 10. For example, the user interface 70 (e.g., the input controls 74) may be used to select a desired welding process, a welding parameter setting (e.g., desired total current output of the welding system 10), a breaker size of the utility 24 or welder 12, the length 34 of the weld power cable 30, and so forth. The display 72 may be used to display selections made by the operator using the interface 70, feedback information from the energy storage caddy 14, or other information. In certain embodiments, the user interface 70 may be a component separate from the energy storage caddy 14. For example, the user interface 70 may be a remote control.
Control of the energy storage caddy 14 and/or the welder 12 by the control circuitry 52 may be based on measured feedback of one or more operating parameters or conditions of the welding system 10. In the illustrated embodiment, the energy storage caddy 14 includes a variety of sensors configured to measure and/or detect operating conditions of the energy storage caddy 14. For example, a first sensor 76 of the energy storage caddy 14 is configured to detect or measure an operating parameter of the power received by the energy storage caddy 14 from the welder 12. The first sensor 76 may measure a current, voltage, or other parameter of the power from the welder 12. Additionally, or alternatively, the control circuitry 52 may received measured operating parameter feedback related to the power provided by the welder 12 from the welder 12 itself (e.g., via the control cable 32).
A second sensor 78 of the energy storage caddy 14 is configured to detect or measure an operating parameter of the power supplied by the energy storage 50. For example, the sensor 78 may measure a current, voltage, or other parameter of the power supplied by the energy storage 50. Similarly, a third sensor 80 is configured to measure a parameter of the combined output power of the energy storage caddy 14. More specifically, the third sensor 80 measures a parameter of the combined power from the energy storage 50 and the welder 12. In other words, the third sensor 80 measures a parameter of the power supplied to the welding operation (e.g., the torch 18).
The energy storage caddy 14 may further include additional sensors configured to measure other operating parameters of the energy storage caddy 14. In the illustrated embodiment, a fourth sensor 82 of the energy storage caddy 14 may be used to measure an operating parameter of the energy storage 50 (e.g., the energy storage device 56). For example, the fourth sensor 82 may measure an amount (e.g., a percentage) of charge of the energy storage device 56.
As mentioned above, the energy storage caddy 14 is configured to regulate, coordinate, and synchronize operation of the energy storage caddy 14 and the welder 12 based on measured feedback (e.g., from sensors 76, 78, 80, 82), user input information or selections, operating conditions of the welding system, and so forth. For example, in one embodiment, an operator may use the user interface 70 to select a desired welding process (e.g., stick welding), select a desired total current output of the welding system 10 for the desired welding process, and a select a breaker size of the welder 12 or the utility 24. In response, the control circuitry 52 coordinates operation of the welder 12 and the energy storage caddy 14 to optimize operation of the welder 12 and the energy storage caddy 14 based in the user input information. For example, the control circuitry 52 may regulate the welder 12 such that the welder 12 produces a first level of output power (i.e., provided to the energy storage caddy 14), and the control circuitry 52 may regulate the energy storage caddy 14 (e.g., the energy storage 50 and the power electronics 54) such that the energy storage caddy 14 produces a second level of output power. The first and second levels of output power may be combined to produce the desired total current output selected by the user. Furthermore, as the charge of the energy storage device 56 (e.g., measured by sensor 82) reduces, the control circuitry 52 may regulate operation of the welder 12 such that the welder 12 produces an increased amount of power to account for a reduction in power production of the energy storage caddy 14. On the other hand, when the energy storage device 56 is at or near a full charge, the control circuitry 52 may control the welder 12 to be in a low idle or sleep mode, while still providing the desired total current output for the welding operation. This optimization in operation of the energy storage caddy 14 and the welder 12 may reduce fuel usage of the welder 12, reduce noise pollution produced by the welder 12, reduce breaker tripping, increase overall total power output of the welding system 10, and so forth.
The control circuitry 52 may also be configured to optimize operation of the welding system 10 in other manners. For example, at the beginning of a welding operation, the welder 12 may be turned off or in a sleep mode. In such circumstances, the energy storage caddy 14 may readily supply a current output (e.g., from the energy storage 50) suitable for beginning a welding operation (e.g., striking an arc with the torch 18). As the energy storage caddy 14 supplies sufficient power to begin the welding operation, the control circuitry 52 may simultaneously send a control signal to the welder 12 to turn on or come out of sleep mode. Thereafter, the welder 12 may begin generating and supplying power to the energy storage caddy 14 for use in the welding operation. In this manner, operation of the welding system 10 may be more streamlined and efficient.
Similarly, in certain circumstances, the control circuitry 52 may be configured to turn off or interrupt operation of the welder 12. For example, for portions of certain waveforms, the caddy 14 may shut off or interrupt the welder 12 and provide power to the welding operation from only the energy storage 50. As will be appreciated, for applications such as plasma welding and regulated metal deposition, long lengths 34 of the weld power cable 30 (e.g., high weld cable inductance) may complicate operation of the welding system 10. As such, the control circuitry 52 may temporarily shut off or interrupt the welder 12 and provide power to the welding operation from only the energy storage 50. This operation enables the welding system 10 to readily and quickly provide a desired current output to the welding operation from a power source (i.e., the energy storage caddy 14) nearby the welding operation, which is not managed by long leads and cables (e.g., the weld power cable 30).
As will be appreciated, the energy storage caddy 14 may be used in other circumstances and operation conditions as well. For example, the energy storage caddy 14 may be capable of providing sufficient power for a welding operation without being coupled to the secondary side 16 of the welder 12. Additionally, in certain embodiments, the energy storage caddy 14 may be configured to supply a background power or voltage (e.g., to maintain a readily available output power) based on a selected welding operation or process. Indeed, the features of the energy storage caddy 14 described above may be used in any combination with one another to enable functionality of the energy storage caddy 14 to provide a variety of different output powers (e.g., alternating current, direct current, etc.) for a variety of different welding process and operations (e.g., stick, MIG, plasma, etc.) in a variety of different operating conditions.
As shown by the graph 100, the total power output of the welding system 10 with the energy storage caddy 14 (i.e., line 108) coupled to the secondary side 16 of the welder 12 is greater than the total power output of the welding system 10 without the energy storage caddy 14 (i.e., line 106). As discussed in detail above, the energy storage 50 of the energy storage caddy 14 may store and discharge power that is combined with a power supplied by the welder 12. Thereafter, the combined power from the energy storage caddy 14 and the welder 12 may be supplied to a welding operation (e.g., the welding torch 18).
As discussed in detail above, embodiments of the present disclosure are directed towards the welding system 10 having the energy storage caddy 14 with one or more energy storage devices 56 running on a secondary connection (e.g., secondary side 16) of the welder 12 or welding power supply. The energy storage caddy 14 may regulate, coordinate, and synchronize operation of the welder 12 and the energy storage caddy 14 to improve efficiency, performance, and versatility of the welding system 10. For example, in certain embodiments, the energy storage caddy 14 may be used to offset or add to an output power or current supplied by the welder 12, thereby increasing the overall power or current output of the welding system 10 while reducing loading on a breaker of the welder 12), reducing noise and fuel usage of the welder 12, and so forth. The energy storage caddy 14 may enable additional improvements to the functionality of the welding system 10. For example, the energy storage caddy 14 may enable the initiation of a welding process or operation while the welder 12 is turned off or in a sleep mode, while the energy storage caddy 14 also controls the welder 12 to turn on or come out of the sleep mode. In this manner, the energy storage caddy 14 enables a more streamlined and efficient operation of the welding system 10.
While only certain features of the present disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14579629 | Dec 2014 | US |
| Child | 17738203 | US |
