Patent Application
20180161910
Devices, systems, and methods consistent with embodiments of the present invention relate to hybrid engine drive welders, and more specifically to engine drive welders and power systems having increased versatility and control options.
The construction and use of engine driven welders is well known. Such welders are often used when utility power grids are either not available or not reliable. In such welders, an engine and generator combination are used to generate power which is used by an output circuit to generate an output power. In an effort to improve on these systems, hybrid engine drive welders have been developed where the welder includes an energy storage device, such as a battery. The battery can be used by the welding system to add to the output power of the system and/or smooth the power provided by the generator to the output circuit—among other uses. Such systems are known and often referred to as hybrid engine drive welders. While advancements have been made for such welding systems to improve their utilization and performance, these systems still have disadvantages in that they are large and their versatility is somewhat limited in certain applications. Thus, improvements are needed to increase the versatility of hybrid engine drive welding systems.
Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such approaches with embodiments of the present invention as set forth in the remainder of the present application with reference to the drawings.
In accordance with one aspect, provided is a welding or cutting device. The welding or cutting device includes an internal combustion engine coupled to a generator for generating electrical power. A welding or cutting power supply is powered by the generator. The welding or cutting power supply generates a welding or cutting output signal. An auxiliary outlet circuit is configured to receive power from the generator. The auxiliary outlet circuit includes at least one auxiliary load outlet. A controller controls an engine speed of the internal combustion engine. The controller is configured to determine an anticipated load on the generator to be supplied through the auxiliary load outlet, based on a no load condition of the auxiliary load outlet, and adjust an idle speed of the engine based on the anticipated load. The controller is further configured to subsequently increase the engine speed, from the idle speed to an auxiliary load speed, when the generator supplies power through the auxiliary load outlet.
In certain embodiments, the controller adjusts the idle speed of the engine from a low idle speed to a higher idle speed based on the anticipated load. The controller can adjust the idle speed of the engine from the low idle speed to the higher idle speed before an auxiliary load connected to the auxiliary load outlet is activated. In certain embodiments, the auxiliary outlet circuit can include a sensor that senses a load connection to the auxiliary load outlet. The sensor can comprise a switch that is activated by the load connection to the auxiliary load outlet. In certain embodiments, the at least one auxiliary load outlet can comprise a first auxiliary load outlet supplying a first voltage level and a second auxiliary load outlet supplying a second voltage level different from the first voltage level, and the controller can be configured to determine a connection of an auxiliary load to either one of the first auxiliary load outlet and the second auxiliary load outlet and adjust the idle speed of the engine to one of a first higher idle speed when the auxiliary load is determined to be connected to the first auxiliary load outlet and a second higher idle speed when the auxiliary load is determined to be connected to the second auxiliary load outlet, wherein the first higher idle speed is different from the second higher idle speed. In certain embodiments, the controller can receive an anticipated power demand signal from an auxiliary load connected to the at least one auxiliary load outlet, and determine the anticipated load based on the anticipated power demand signal.
In accordance with another aspect, provided is a welding or cutting device. The welding or cutting device includes an internal combustion engine coupled to a generator for generating electrical power. A welding or cutting power supply is powered by the generator, wherein the welding or cutting power supply generates a welding or cutting output signal. An auxiliary outlet circuit is configured to receive power from the generator, wherein the auxiliary outlet circuit includes a first auxiliary load outlet supplying a first voltage level and a second auxiliary load outlet supplying a second voltage level different from the first voltage level. A controller controls an engine speed of the internal combustion engine. The controller is configured to determine a connection of an auxiliary load to either one of the first auxiliary load outlet and the second auxiliary load outlet, and adjust an idle speed of the engine to one of a first idle speed when the auxiliary load is determined to be connected to the first auxiliary load outlet and a second idle speed when the auxiliary load is determined to be connected to the second auxiliary load outlet. The first idle speed is different from the second idle speed.
In certain embodiments, the controller is configured to increase the engine speed from said one of the first idle speed and the second idle speed to an auxiliary load speed upon activation of the auxiliary load. In certain embodiments, the controller adjusts the idle speed of the engine from a low idle speed to said one of the first idle speed and the second idle speed. The auxiliary outlet circuit can include a sensor that senses the connection of the auxiliary load to the at least one of the first auxiliary load outlet and the second auxiliary load outlet. The sensor can include a switch that is activated by the connection of the auxiliary load to the at least one of the first auxiliary load outlet and the second auxiliary load outlet. In certain embodiments, the controller receives an anticipated power demand signal from the auxiliary load and adjusts the idle speed of the engine based on the anticipated power demand signal.
In accordance with another aspect, provided is a welding or cutting system. The welding or cutting system includes a power generation system. The power generation system includes an internal combustion engine coupled to a generator for generating a power signal. A welding or cutting power supply is powered by the generator. The welding or cutting power supply generates a welding or cutting output signal. A power conversion circuit receives said power signal and generates a synchronous output signal. An outlet circuit has at least one outlet which is coupled to said power conversion circuit and receives said synchronous output signal. A first controller controls an operation of at least said internal combustion engine. A first communication module is coupled to said first controller. An auxiliary electrical load is coupled to said at least one outlet and is powered by said synchronous output signal. The auxiliary electrical load includes a second controller, and a second communication module, coupled to said second controller, that is in communication with said first communication module. Said second controller determines an anticipated power demand for a given operation of said auxiliary electrical load and generates and sends an anticipated power demand signal to said first communication module. Said first controller uses said anticipated power demand signal to adjust an idle speed of said internal combustion engine from a first idle speed to a second idle speed before said anticipated power demand is supplied by the generator.
The first controller can adjust the idle speed of the engine from a low idle speed to a higher idle speed based said anticipated power demand signal. Further, the at least one outlet can include a first auxiliary load outlet supplying a first voltage level and a second auxiliary load outlet supplying a second voltage level different from the first voltage level.
In accordance with another aspect, provided is an electrical power generation device. The electrical power generation device includes an internal combustion engine coupled to a generator for generating electrical power. An outlet circuit is configured to receive power from the generator, wherein the outlet circuit includes a first outlet supplying a first voltage level and a second outlet supplying a second voltage level different from the first voltage level. A controller controls an engine speed of the internal combustion engine. The controller is configured to determine a connection of a load to either one of the first outlet and the second outlet, and adjust an idle speed of the engine to one of a first idle speed when the load is determined to be connected to the first outlet and a second idle speed when the load is determined to be connected to the second outlet. The first idle speed is different from the second idle speed.
In certain embodiments, the controller is further configured to increase the engine speed from said one of the first idle speed and the second idle speed to a load speed upon activation of the load. The controller can further adjust the idle speed of the engine from a low idle speed to said one of the first idle speed and the second idle speed. The outlet circuit can include a sensor that senses the connection of the load to the at least one of the first outlet and the second outlet.
The above and/or other aspects of the invention will be more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings, in which:
Reference will now be made in detail to various and alternative exemplary embodiments and to the accompanying drawings, with like numerals representing substantially identical structural elements. Each example is provided by way of explanation, and not as a limitation. In fact, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the scope or spirit of the disclosure and claims. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure includes modifications and variations as come within the scope of the appended claims and their equivalents.
The present disclosure is generally directed to hybrid engine drive welders using a gas or diesel powered engine to power a generator, which generates power for a welding operation. Further, exemplary welders can also generate auxiliary power which can be used to power accessories connected to the welder. Further, exemplary embodiments can use the generator power to provide energy to an energy storage device (e.g., a battery) which can store energy and provide that energy to the output power of the welder as needed. However, exemplary embodiments of the present invention are not limited to power supplies which provide a welding power but can also be used to provide a cutting power or any other power as desired.
Turning now to
Turning now to
As shown in
An engine control system 270 is provided to control the operation of engine 200. The engine control system receives a signal via line 272 from the battery system, which signal is representative of the charge on the battery system. When the battery system is fully charged, the engine control system slows or turns off engine 200. When the battery system is less than fully charged and/or below a predefined charge level, the engine control system causes the engine to increase in speed and/or be turned on.
Weld control 250 controls the chopper welding output via signal 252 based upon output current information received via line 254.
An open circuit detector 280 is provided to determine whether an arc is being formed or is about to be formed between the electrode and workpiece during a welding operation. When open circuit detector 280 does not detect an arc, the open circuit detector causes the chopper module 240 to turn off, thereby reducing a drain of power from the battery system. In one non-limiting design, the voltage level between the workpiece and electrode is monitored to determine the current state of the arc.
As illustrated in
As can be appreciated from the design and operation of the hybrid energy source for welder A, the size of engine 200 and electric generator 210 need not be sized to provide the maximum welding output rating of the welder. The size of engine 200 and electric generator 210 only needs to be sufficiently sized to provide enough current to the battery of battery system 230 to adequately recharge the battery after the battery has been partially discharged when forming an electric arc. For instance, if the maximum welding output rating of a welder is 10 kW of power, and the maximum average duty cycle for a welding operation is 40%, the engine and electric generator only needs to produce sufficient current to supply 40% of the maximum welding output rating since only this much current is being discharged by the battery system during a particular duty cycle for the welder. As a result, the size of the engine and the size of the electric generator can be significantly decreased by using the hybrid energy source of the present invention. In addition to the cost savings associated with using a smaller engine and electric generator, the efficiency rating for the use of the current generated by the electric generator is significantly increased since most of the current is used to recharge the battery after it has been partially discharged during the formation of an electric arc. In the past, only 20-40% of the current generated by the electric generator was used in welding operations when the duty cycle was about 20-40%. In addition to the increase in energy usage efficiency, the size of the motor needed to provide sufficient power to meet the maximum welding output rating of the welder is decreased since a smaller engine is needed to power the hybrid energy source. Another benefit of the hybrid energy source is the ability of the welder to generate a welding current without having to operate engine 200 and electric generator 210. When battery system 230 is fully charged, the battery system has an adequate amp-hour size to provide the welding arc requirements during a particular period of time. As a result, the welder can be used in locations where the running of an engine powered welder is unacceptable due to noise and/or engine exhaust issues.
Turning now to
The system 300 is comprised of two modular sections 300′ and 300″, each of which can be fully enclosed in a housing 310 (like the one shown in
As shown in
Removably coupled to the primary module 300′ is a removable power module 300″. The removable power module 310″ contains at least an energy storage device 331 (similar to 230), another controller 333 (see, e.g., item 250 in
Further, as shown in
Further, the power module 300″ also has a communication device 339 which is similar to the device 329 in the primary module 300′. The communication module 339 allows the power module 300″ to communicate, either wirelessly or via a wired connection, with the primary module 300′ and any other appropriate device. For example, a remote control device or pendant (not shown) can be used to communicate with the primary and power modules. The pendant/remote controller can be used to monitor the operation, function of the modules and/or control their operation.
Because the power module 300″ is removable the internal structure of the system 300 can have a track or rail structure (not shown) that allows the power module 300″ to be easily removed and reinserted as needed. The track/rail system also allows the power module 300″ to be engaged with the primary module consistently so that the connections 341 and 342 can be consistently made.
In some exemplary embodiments, the power module 300″ communicates (via the device 339) with the primary module 300′ while they are separated from each other. In such embodiments, the status of the power module 300″ can be monitored on the user interface 327. Further, the user interface 327 can be used to control the operation of the power module 300″ via the communication devices 329 and 339. In exemplary embodiments, the controller 325 monitors the usage of the module 300″ via the communication devices and when the energy storage device 331 gets below a threshold charge level the controller 325 starts the engine 321 to and prepares the module 300′ to charge the device 331 upon return the of module 300″. For example, either (or both) of the controllers 325/333 can determined a remaining usage time or a charge level of the storage device 331 (e.g., below 10% charge, or less than 10 minutes of usage time remaining), and based on that determination cause the engine to be started automatically in anticipation of the returning module 300″. This will save time by having the primary module 300′ prepare for a charging operation prior to the physical connection of the two modules. Similarly, in other exemplary embodiments, a user can use the user interface 339 on the power module 300″ to turn on the engine 321 via the communication devices 329/339 and thus have the primary module 300′ warmed up and ready for charging prior to engagement of the two modules. For example, during use of the power module 300″ a user notices that the energy charge level of the storage device 331 is below a desired level. The user can then use the interface 337 to start the engine 321 of the primary module 300′ so that the recharging of the device 331 can begin as soon as the module 300″ is recoupled with the module 300′.
In other exemplary embodiments, the communication devices 329 and/or 339 have mobile communication and GPS location capabilities, so that their respective locations can be determined relative to each other. This will allow a user of the primary module 300′ to easily locate the power module 300″ that is associated with the system 300. The implementation of mobile GPS positioning technology is generally known and need not be discussed in detail herein. In other exemplary embodiments, the GPS positioning information can be used to disable the functionality of the power module 300″ if the power module 300′ is moved to a location which is outside of a desired range. For example, it may be desirable to keep the power module 300″ within 200 yards of the primary module 300′, and when either or both of the controllers determined that this distance has been exceeded the function of the power module 300″ can be disabled. This can aid in preventing theft, or otherwise moving the power module to an undesired location.
In some exemplary embodiments, a cable connection 360 can be provided between the primary module 300′ and the power module 300″ to allow for remote charging of the battery 331. In such embodiments, a cable 360 can be coupled at the connections 344 to provide the charging energy to the battery 331. Additionally, in such embodiments, the cable 360 can allow for the full welding operation of the system 300 (for example, using the generator power to provide the welding power) while the module 300″ is positioned remotely from the module 300′.
The synchronized output power signal from the output circuit 413 is neither a welding or cutting signal, but is a synchronized power signal that can be used by various loads (power supplies, devices) that are typically coupled to utility grid power outlets or other synchronized load sources. Each of the loads 420 and 430 are capable of using the synchronous output signals to power their operation. The controller 414 is used to control the operation of the power supply 410 and is coupled to the user interface 415, which can be used by the user to control the operation of the power supply 410, and the other components as shown. Further, the power supply 410 has a communication device 416 which is capable of transmitting and receiving data from any of the loads 420/430 (each of which has its own communication device—421 and 431, respectively). Further, the communication device 416 can allow for communication with remote control/pendant devices and the like to allow for remote monitoring and control of the system 400 and the power supply 410. It should be noted that each of the exemplary loads, like the power supply 430 and the wire feeder 420, can be constructed like known systems, which include controllers, power conversion circuitry, etc. that are known to be used by such systems to accomplish their intended function. In each case, the controllers (not shown) of the feeder 420 and power supplies 430 are coupled to the respective communication circuits 421/431 so that status (and other information) of the devices 420/430 can be communicated to the controller 414. This is discussed further below.
In exemplary embodiments of the present invention, the power supply 410 communicates with each of the loads 420 and 430 (in the example shown a wire feeder and welding power supply) and each of the loads provide a predicted or anticipated load/power demand to the power supply 410 so that the power supply 410 can prepare for the load demand. This is explained further below.
In known engine/generator systems a synchronous power signal can be generated. However, with these systems the engine/generator system does not optimize the output of the synchronized power signal (e.g., 230 VAC) for dynamic conditions. For example, the welding output for a connected welding device may be set to a high load/demand setting, but the engine/generator system providing the power may only be set at a low idle setting. This can create power/demand issues when there are high power demand operations, such as when a welding arc is struck.
Embodiments of the present invention address this, and other issues, by having the connected devices 420 and 430 communicate with the power supply 410 so that the power supply 410 is provided with an anticipated load demand and so that it can be ready to provide the desired power level when needed.
For example, as shown in
For example, if the load 430 is a welder or a plasma cutter, it may be set for an operational level which requires a high power demand at arc ignition. If the power supply/generator 410 is set at a low idle speed, this setting may not be sufficient to provide for smooth transition to the high energy demand of the load 430, during strike or arc ignition. Embodiments of the present invention address this issue by allowing for predictive communication between the load 430 and the power supply/generator 410 to ensure a proper operation of the loads. A discussion of an exemplary operation of the system 400 is set forth below.
In the system 400, when a load like a welding/cutting power supply 430 is coupled to the generator 410 a communication link is made between the components such that the power supply/generator 410 recognizes that the load 430 is coupled to it. This communication link can be made over the cable connection 450/451 between the components. The welding/cutting power supply 430 then communicates its power settings and/or changes in its power settings to the controller 414 of the power supply/generator 410, so that the controller can adjust the output of the power supply and/or the engine RPMs appropriately. For example, if the welding power supply 430 is set to weld at a current level of 200 amps or higher this information is communicated to the controller 414. Using this information, the controller 414 determines whether or not the engine RPMs are at the proper speed to ensure that the power demands of the welder for its operation/start are sufficiently met. If the RPMs of the engine are not at a proper RPM level, the controller 414 causes the engine speed to increase to the desired setting. Similarly, in other exemplary embodiments, if the engine RPMs are high relative to the power demand based on the settings of the load 430, then the controller 414 can slow the engine 411 so that fuel is not wasted.
Thus, in exemplary embodiments, the power supply 410 and the load 430 communicate with each other and the controller 414 of the power supply/generator 410 uses these communications to control the engine 411 and the operation of the power supply 410. That is, the controller 414 can use settings and/or operational set points of the load 430 to control its operation. In exemplary embodiments, if the controller determines that the RPM settings is too low it will cause the RPMs to increase, if the controller 414 determines that that the current RPM setting is acceptable then no change will be made, and if the controller 414 determines that the RPMs are too high, creating unneeded energy then the controller causes the engine to slow down. This ensures that an optimal engine RPM setting is maintained as needed and that any welding or cutting operation made via the load 430 is performed without any difficulty.
In further exemplary embodiments, the controller 414 can use predictive information from the power supply 430 to vary its output and/or engine operation during a welding operation. For example, the welding power supply 430 can communicate to the power supply 410 that a welding operation is about to start, and communicates information about the welding operation that is used by the controller 414 to control the operation of the power supply—including the welding operation type (pulse, stick, CC, CV, etc.), the average current for the welding operation etc. With this information the controller 414 causes the engine/generator and output circuit to prepare to deliver the power needed to start a welding operation. In many instances, because of the high current demand for an arc start, the output power needed at the start of a welding operation can be higher than that needed for the main portion of the welding operation. Thus, in such exemplary embodiments, the controller 414 causes the power supply 410 to prepare for an arc start—and the associated power demand (e.g., increase engine speed, etc.) and then once the arc start is confirmed by the welding power supply 430 to the power supply 410, the controller 414 can cause the engine 411, and other components, to settle into a mode of operation needed for the welding operation. For example, the controller 414 can determine—prior to a welding operation beginning—that for a given welding operation the engine 411 will need to provide 1,500 RPMs for the arc start aspect of the weld process, but after the arc starts the engine will only need to provide 1,200 RPMs for the remainder of the weld process. Thus, once the arc start is communicated, the controller 414 causes the engine 411 to slow down as needed. This has the advantage of optimizing the use of the engine 411, and the power supply 410.
In further exemplary embodiments of the present invention, the controller 414 does not cause a change in engine RPM until the demand is actually needed. For example, in any given welding/cutting operation there may be an appreciable delay between inputting the operational settings on the welder/cutter 430 and actually performing the operation. Thus, it is unnecessary to have the RPMs of the engine 411 increased if the actual demand for the increased RPMs will not be needed for a period of time. Therefore, in some exemplary embodiments of the present invention a user can generate an input signal either on the welder 430 and/or on a torch/gun 460 coupled to the welder 430. For example, a user can input a current setting at the welder 430 of 300 amps for a given welding operation. This setting can be communicated to the power supply 410 and/or the controller 414 can query the controller of the welder 430 to obtain its operational settings. Based on this information, the controller 414 determines the appropriate RPM setting for the engine to ensure the appropriate power is available to the load 430. However, the controller 414 does not initiate the RPM change (if needed) until a user input is received that the welding/cutting process is about to begin. For example, the user can interact with a user input panel/device on the load/welder 430 or on a torch 460. This interaction can send a signal to the controller 414 indicating that the load demand will be imminent and so the controller 414 causes the engine RPM speed to change to the desired level. For example, the torch/gun 460 can have a switch 461 which is activated by the user to indicate that he/she is ready to begin the operation. This data input can be used by the controller 414 to increase the RPMs. For example, the system can be configured such that the controller 414 will not make any changes to the output power of the power supply 410 and/or any change in engine speed until after a predetermined period of time after a user input. In some exemplary embodiments, this time can be in the range of 1 to 10 seconds. As an example, (1) a user enters information about a welding operation to the welding power supply 430; (2) this information is communicated to the controller 414, along with any load information for any other device—such as a wire feeder 420; (3) the controller 414 uses this information to determine an appropriate output power and/or frequency for a welding operation, along with an appropriate RPM speed for the engine 411; (4) the controller waits to detect a user input indicating that the process is about to begin—for example, from a switch 461 on the gun 460, power supply 430, or any other means; (5) after an amount of time—e.g., between 1 and 10 seconds—the controller 414 causes the engine speed to change (if needed) so that the appropriate power can be provided by the power supply 410; and (6) the welding process can begin. Similarly, exemplary embodiments can use similar user input to slow down/shut off the power supply 410 when the power output is not needed. For example, the power supply 430 can communicate to the controller 414 that the load is no longer needed and/or a user input can indicate that the higher power output is not needed. As an example, when a user is done welding the user can use the same switch 461 on the gun 460 or on the power supply 430 to indicate that the process is completed and the controller 414 uses this indication to slow down the engine 411 to an idle speed to wait for the next operation. This can greatly increase the operational efficiency of the power supply 410.
In further exemplary embodiments of the present invention the controller 414 can operate the system 410, including the engine 411, to provide a synchronous output power which exceeds the determined anticipated power or load demand. This is done to account for situations in which there may be unexpected peaks or spikes in the power demand or other unexpected increases in the demand for the synchronous power—which could also include the turning on, or plugging in, of another device in the outlet circuit 417. For example, if it is determined by the controller 414 that the synchronous output of the system 410 needs to be 5 kW based on information from the devices 420/430, the controller 414 controls the engine 411 such that an output power of 5.25 kW is provided—a 5% increase. This can aid in smoothly dealing with unexpected power demands/spikes. In some embodiments, the controller 414 can control the engine such that at least a 3% power increase is provided over the total anticipated load, while in other embodiments at least a 5% increase is provided. In even further embodiments, at least a 10% power increase can be provided. Further, in some embodiments, the % increase over the determined power need can be based on the type of load, or other information, from the devices 420/430. For example, if a welding/cutting process is to be used that has a relatively low chance of requiring power spikes, the controller 414 can controller the engine 411 such that only a 3% power increase is provided above the anticipated load, but if the process has an increased chance of requiring power demand spikes, the controller 414 can set the engine speed 411 such that at least a 10% increase in the available synchronous power is provided. Thus, in such embodiments, the controllers of the systems—such as the power supply 430—communicates a type of process to be performed, or any type of procedure or process identifier—which is used by the controller 414 to determine an available power increase factor. That is, for example, for some processes/procedures the controller 414 will use a 3% power increase factor, for others it will be a 5% increase factor, and yet for others it will be a 10% increase factor. In further embodiments, this increase factor can be set by a user via the user interface 415.
In a further exemplary embodiment, the switch 461 can also be the trigger that is commonly used on known torches/guns. For example, the user can initiate a quick double-toggle of the trigger 461 and this double-toggle signals to the controller 414 that the process is about to begin, at which time the controller 414 initiates the needed RPM change. After the double-toggle the user would wait for a period of time before starting to give the engine 411 time to reach the desired RPMs. For example, the user can wait 1 to 10 seconds and then begin the desired operation. Again, a second double toggle can be used to indicate that the process has been completed and that the engine can slow down.
In another exemplary embodiment, the torch/gun 460 can have an indicator 462 which will provide a visual indication to the user that the engine 411 is at the appropriate RPMs for the desired operation, and upon seeing the indication the user can begin the desired operation. For example the indicator 462 can be an LED, or similar type device, which can glow green, or any other desired color, to indicate to the user that the generator 410 is at the appropriate power level for the given operation. The indicator 462 can also be used to provide other indications, including: (1) an indication that the power supply 410 is not ready (e.g., red); and/or an indication that the welding/cutting process is reaching/exceeding the output capacity of the power supply 410 (e.g. a flashing red indicator). Of course, other indications can also be provided.
With these exemplary embodiments, a welding/cutting power supply 430 can be coupled to a generator 410 which provides a synchronous output signal via outlets 418 and the system 400 ensures that the needed output power is available at the outlets 418 when needed to ensure proper cutting and/or welding operations. Of course, it should be noted that other exemplary embodiments not be limited to using welding or cutting power supplies, but other devices which require a synchronous power signal can be coupled to the generator/power supply 410 and operate similar to the discussions set forth above.
As shown in
It is also noted that further exemplary embodiments need not be limited to welding/cutting applications, and exemplary embodiments similar to that shown in
The loads plugged into the outlet circuit 417 can be auxiliary loads. Auxiliary loads, such as lights, tools, etc. may lack the ability to communicate with the controller 414 in the engine drive power supply 410. In certain embodiments, the controller 414 can recognize that a load has been plugged into the outlet circuit 417 and adjust the speed of the engine 411 accordingly. The outlet circuit 417 can include one or more sensors 470 that sense a load connection to an outlet 418. For example, the outlet circuit 417 can include mechanical switches associated with respective outlets 418 that are actuated when a load is plugged into the outlet, such as by the prongs of a plug. The load connection could also actuate the switch by requiring the movement of a door or shutter connected to the switch and blocking the openings in the outlet, before the load is plugged into the outlet 418. Various types of sensors could be used to determine that an auxiliary load has been connected or plugged into to an outlet 418. Further, such sensing can be combined with communications between the auxiliary load and the controller 414 in the engine drive power supply 410. Thus, in certain embodiments, the controller 414 can sense the load connection to an outlet, and the load can also communicate an anticipated power demand for a given operation to the power supply 410.
The controller 414 can determine an anticipated load on the generator 412, to be supplied to an auxiliary load through the outlet 418, before the auxiliary load is activated. For example, based on the voltage and current ratings of the auxiliary outlet to which the auxiliary load is connected, the controller 414 can determine an anticipated load on the generator 412. The anticipated load will be higher when the auxiliary load is connected to a 240V, 50 A outlet as compared to a 120V, 20 A outlet, for example. The controller 414 can determine, based on the states of the sensors 470, which outlet(s) are connected to auxiliary loads, and from that determine the anticipated load on the generator. The controller 414 can determine the anticipated load through a calculation or via stored values or lookup table stored in a memory accessible by the controller. The controller 414 can determine the anticipated load before the auxiliary loads are activated, based on a no load condition of the outlets 418 from the state of the sensors 470. The controller 414 can further determine the anticipated load based on any power demand signals received from auxiliary loads.
Based on the anticipated load on the generator, as determined from connected auxiliary loads, welding/cutting power supply settings, received power demand signals, etc., the controller 414 can adjust an idle speed of the engine 411. The default engine 411 idle speed may be a low idle speed (e.g., between 2200-2600 rpm). However, it could be difficult for the engine 411 to quickly increase its speed from a low idle speed to an operating speed under load (“auxiliary load speed”). The controller 414 can increase the idle speed of the engine 411 to accommodate an anticipated auxiliary load and decrease the jump in speed (from idle to auxiliary load speed) required of the engine when the auxiliary load is activated and draws power from the generator. The controller 414 can operate the engine 411 at various different idle speeds based on the size of the anticipated load (e.g., faster idle speeds for higher anticipated loads and slower idle speeds for lower anticipated loads). Further, the idle speeds corresponding to anticipated loads can be higher than the low idle speed, so that the controller 414 increases the engine speed from the low idle speed to a higher idle speed. The idle speed increase occurs before the auxiliary load is actually applied (e.g., before the auxiliary load is activated). Once the auxiliary load is applied or activated, the controller 414 can further increase the engine speed from the adjusted idle speed to an operating speed (e.g., the auxiliary load speed), when the generator 412 supplies power through the outlet 418 for example. The engine drive power supply 410 can include sensors, such as current sensors, voltage sensors, etc., to determine when an auxiliary load is activated.
The controller 414 can run the engine 411 at different idle speeds based on the voltage/current rating of an outlet 418 to which an auxiliary load is connected. Outlets 418 having a higher voltage and/or current rating can have a higher associated engine idle speed than outlets having a lower voltage and/or current rating. For example, the controller 414 might initially operate the engine 411 at a low idle of 2200 rpm when no connected loads are sensed at any of the auxiliary outlets 418. If a load is plugged into a 120V, 20 A outlet, the controller 414 can increase the engine speed to a first higher idle speed, such as 2600 rpm. If a load is instead plugged into a 240V, 50 A outlet, the controller 414 can increase the engine idle speed to a second higher idle speed that is higher than the first higher idle speed, such as 2700 or 2800 rpm for example. Upon activation of the auxiliary load, the engine 411 speed can be further increased from the higher idle speed to the auxiliary load speed. The auxiliary load speed could correspond to a 50 Hz or 60 Hz output from the generator 412, such as 3600 rpm. The auxiliary load speed could also be other speeds, in particular if the output circuit 413 generates 50 Hz or 60 Hz power, such as via an inverter.
Further, in additional exemplary embodiments, the controller 414 can speed up the engine 411 (consistent with the discussions above) prior to engaging a clutch between the engine 411 and the generator 412, such that the engine reaches the desired RPMs before the clutch is engaged. Because the use of clutches to couple generators and engines is well known, their use and structure need not be described herein.
As discussed above, the use of engine drive system with energy storage devices is generally known. In these systems, the engine and generator are used to recharge an energy storage device (e.g., battery) used in the system to provide power to the welding/cutting operation. However, in most systems the engine-generator combination is capable of outputting more power than the charging rate of the energy storage device. Thus, in situations where there are multiple hybrid engine drive welders/generator present the additional engine capacity is not being used efficiently. Exemplary embodiments of the present invention address this by efficiently using excess energy.
As shown, each of the generators 510/520 can be similarly constructed, in that they each can contain an engine 511/521, generator 512/522, output power circuit 513/523, an energy storage device 514/524, a controller 515/525, a user interface 516/526, and a communication device 517/527. The generators 510/520 can be used to generate welding and/or cutting power and provide that output power to a load, such as a welding or cutting operation.
As shown in
As stated above, a typical engine/generator combination can generate power that exceeds the recharge rate of a storage device. Thus, in exemplary embodiments of the present invention, when multiple storage devices 514/524 are in need of charging, a single engine/generator can be used to charge both devices 514/524. In such embodiments, at least one controller 517/527 (which can be in a slave-master relationship) can determine that the storage devices 514/524 are in need of charging, and that the output power of a single generator 512 is sufficient to charge both storage devices 514/524. When this determination is made by the controller 515 and is communicated to controller 524, the controller 524 causes the engine 521 to be shut off, or at least reduced to an idle, or low idle speed so that the charging of both devices 514/524 is performed by only one engine/generator combination (e.g., items 511 and 512). This saves fuel in the second power generator 520, as the engine 521 need not run to charge the battery 524 in that system. This configuration is much more efficient than known systems.
In further exemplary embodiments, a single engine/generator combination can be used even when there are loads on each of the respective systems 510/520. For example, in certain situations a single engine/generator combination (e.g., 511/512) can generate enough average power to for the loads on each of the power supplies 510 and 520, such that, again, only a single engine need run to perform two welding operations. Thus, in exemplary embodiments, the output from a single engine/generator combination can be used to provide the output power for more than one engine-drive power generators (e.g., welders). In such embodiments, at least one of the controllers evaluates the load demand for each of the welders 510/520 and determines if a single engine/generator combination can supply the average power output to satisfy both loads. In further exemplary embodiments, at least one of the controller(s) compares for the power needed for both loads with the average power available from a single engine/generator combination and each of the respective storage devices 514/524 to determine if enough average power is available to sustain both loads as required with only a single engine running. If the combined loads have a power requirement before the available average power, then a single engine/generator combination is operated to provide the power to the loads (which can be welding or cutting operations, or a combination thereof). If the controller(s) determines that the loads require a higher average power than that available from a single engine/generator combination can provide, then the controller(s) can cause the other of the engine/generator combinations to provide the additional power needed. In such exemplary embodiments, the controller(s) can control the RPMs of the engines to ensure that the system 500 runs as efficiently as possible. That is, in some power demand applications it will be not necessary to run each system 510/520 at its full capacity, and thus waste fuel. For example, a controller(s) may determine that one engine 511 will need to run at full power while the other 521 only needs to operate at a lesser idle speed to provide the needed power. This, again, optimizes fuel efficiency while delivering the appropriate amount of power needed for both loads.
Thus, with the above described configuration, embodiments of the present invention can communicate respective storage device charge levels, available power output, and/or load information and demand between the controllers 515/525 so that the controllers can control the operation of the systems 510/520 in an optimal way.
In some exemplary embodiments, a control methodology can be used to ensure that an appropriate amount of power is available for a given operation. For example, if the system 520 is the only system being used for a given welding/cutting operation, but its load demand is near the capacity of the system 520, the other system 510 can be running, at a desired level, to provide any excess power as may be needed during a given operation. That is, if a given operation/load is close to the maximum output capacity of a single system 510/520, the other system can be running to provide any needed additional power, if a spike in power demand is needed. For example, if the power supply 510 is being used in an operation which requires between 90 and 100% of the maximum output power of the supply 510, the controllers 515/525 cause the power supply 520 to be running, at least in an idle state, to be ready for any conditions/events, that may cause the power demand by the load to spike over 100% of the maximum output power of the system 510. This can occur, for example, during short circuit events, restrikes, or any other events requiring a high power output for a limited duration. Thus, exemplary embodiments of the present invention allow the system 500 have the desired available power for needed events, while optimizing fuel and system efficiency. Of course, it should be noted that the output frequency of the systems 510/520 should be synchronized when providing output to a single load. In the embodiment discussed above, the second system 510/520 runs when the output of the operating system 510/520 is in the range of 90 to 100% of its maximum power output. However, in other exemplary embodiments, this range can be expanded, for example in the range of 85 to 100% of its rated maximum output power. Further, in exemplary embodiments of the present invention, the maximum rated output power may not be the absolute maximum output power for a system 510/520, but can be a set or predetermined maximum output power rating based on the construction and operation of the system and can be a power level at which normal operation of the system 510/520 can be sustained at an acceptable duty cycle. Of course, the maximum power output rating can be defined in other ways, without departing from the spirit or scope of the present invention.
In further exemplary embodiments, the controllers 515/525 can communicate relative fuel levels of each respective system 510/520. With this information, the controller(s) can determine which of the system 510/520 will be used to recharge both batteries and/or provide the loads for each of the system 510/520. For example, in an exemplary embodiment, the controller 515 can be the primary controller such that the system 510 is the default primary system to provide power when the engine 521 of the other system 520 is not running. The controller 515 monitors the fuel level in the system 510, such that when the fuel level drops below a threshold level the controller 515 will communicate with the controller 525 to cause the engine 521 to start up, assuming that the system 520 has a sufficient fuel level. This will allow for an uninterrupted supply of power to the respective loads and/or charging of the storage devices 514/524 without the need for user intervention to refill a gas tank.
The fuel threshold level can be preprogrammed and/or can be set by a user. In exemplary embodiments, the fuel threshold level is set above a zero fuel level to ensure that an engine does not run out of fuel. Thus, the controller(s) can determine which engine to run based on respective fuel levels in the respective systems 510/520. It is noted that the fuel tanks are not shown for reasons of simplicity, but the use and installation of fuel tanks in engine driven welder/generator are well known. In further exemplary embodiments, the controllers 515/525 can also share/communicate fuel efficiency information between the systems 510/520. This allows the controller(s) to determine which engine 511/521 to run based on the relative fuel efficiency of the systems 510/520. For example, the system 510 can have a better fuel efficiency at a given load demand, where the load demand is shared between the two systems 510/520. Based on this information, the controller 515 determines that the engine 511 and generator 512 will be operated to provide the power, while the engine 521 will not be operated. Then if the total load demand changes to a different level (either higher or lower) at which the system 520 is more fuel efficient, the controller 515 (and/or 525) can cause the engine 521 and generator 522 to turn on and provide the power, while shutting off the engine 511. This allows the system 500 to optimize fuel efficiency across a wide range of load demand situations, not currently obtainable by current systems. This also allows a system 500 to be used where each of the individual systems 510/520 have different fuel efficiencies at different power output ranges.
In further exemplary embodiments, the controllers 515/525 can also share error and status information of the systems 510/520. For example, the controllers 515/525 can share error or status information for their respective engines and generators, such that when an error is detected in one system 510 or 520, the controller(s) cause the power to be supplied by the other, non-fault, engine and generator combination. This ensures that the power to the respective loads can be provided, even though an error may exist in one of the systems 510/520. Thus, embodiments of the present invention can allow two separate welding operations to continue even though one of the engines and/or generators has failed. Further, this system allows for multiple energy storage devices 514/524 to be charged even though one engine/generator combination has failed or has performance issues.
In further exemplary embodiments, each of the systems 510/520 can be set up to run different processes at the same time. For example, the system 510 can be set up to run a STT type welding process, while the system 520 can be set up to run a pulse welding process (or any other different process), and if it is determined (by one or both of the controllers) that only one engine/generator is needed to provide the needed power, then one engine is run, and two different welding processes can be provided at the same time.
In view of the above, systems such as those shown in
It should be noted that while the above embodiments related to
With referring to
While the claimed subject matter of the present application has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the claimed subject matter. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the claimed subject matter without departing from its scope. Therefore, it is intended that the claimed subject matter not be limited to the particular embodiment disclosed, but that the claimed subject matter will include all embodiments falling within the scope of the appended claims.
This application is a continuation-in-part of U.S. patent application Ser. No. 14/820,180, filed on Aug. 6, 2015, the disclosure of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14820180 | Aug 2015 | US |
| Child | 15891698 | US |
