Welding power supply with half bridge

• US 10,549,374 B2
• Filed: 12/31/2015
• Issued: 02/04/2020
• Est. Priority Date: 12/31/2015
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Henry, Andrew J.
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Sims, III, James F
• Application Number:
  US14/986,284
• Publication Number:
  US 20170189986A1
• Time in Patent Office: 1,496 Days
• CPC Class Codes: B23K 9/1062 with computing means
• CPC Class Codes: B23K 9/1075 Parallel power supply, i.e. multiple power supplies or multiple inverters supplying a single arc or welding current
• CPC Class Codes: H02M 1/0029 Circuits or arrangements for limiting the slope of switching signals, e.g. slew rate
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 7/4807 having a high frequency intermediate AC stage
• CPC Class Codes: H02M 7/538 in a push-pull configuration H02M7/5375 takes precedence ; with oscillating arrangements H02M7/53832, H02M7/53846
• CPC Class Codes: H02M 7/5387 in a bridge configuration

Abstract

A method and apparatus for providing welding-type power is disclosed. The apparatus includes an input circuit, a dc bus, an output circuit, and a control module. The input circuit receives power and provides an intermediate signal to the bus. The output circuit receives the dc bus and provides an ac welding-type output. The output circuit includes a half-bridge output inverter with at least first and second switches. The output inverter further includes an output control circuit. The output control circuit provides freewheeling paths that includes control switches, the output, antiparallel diodes. The control module has a four quadrant control module that provides control signals to the half bridge output inverter and provides modulating control signals to the first and second output control switches. The modulating signals cause the output control switches to be turned on and off multiple times to control a rate of change of output current.

Claims

1. A welding-type power supply, comprising:

an input circuit, disposed to receive input power, and to provide an intermediate signal;

a dc bus disposed to receive the intermediate signal;

an output circuit, disposed to receive the dc bus, wherein the output circuit provides an ac welding-type output across an electrode output and a work output, and includes a half-bridge inverter having at least a first switch and a second switch, wherein the half bridge inverter is connected to receive power from the dc bus and to provide power to the output, and further wherein the output circuit includes a commutation circuit connected to provide a first freewheeling path that includes a first commutation switch, the electrode output, the work output and a diode antiparallel to the first switch; and

a control module including an inverter control module that provides control signals to the half bridge inverter, and further including a commutation control module that provides modulating control signals to the first commutation switch, wherein the modulating control signals cause the first commutation switch to be turned on and off multiple times during a first single commutation of a current to the first switch, whereby a first rate of change of a current in the output is controlled.

2. The welding-type power supply of claim 1, wherein the commutation circuit includes a second commutation switch that provides a second freewheeling path that includes the second commutation switch, the electrode output, the work output and a second diode antiparallel to the second switch, wherein the commutation control module provides the modulating control signals to the second commutation switch, and wherein the modulating control signals cause the second commutation switch to be turned on and off multiple times during a second single commutation of the current from the first switch to the second switch, whereby a second rate of change of current in the output is controlled.

3. The welding-type power supply of claim 2, further comprising an output inductor disposed such that current in the output inductor also flows across the work output and the electrode output and at least one of the first switch and the second switch.

4. The welding-type power supply of claim 3, wherein the input circuit includes at least one of an energy storage device, a battery, generator, a transformer, a converter and a boost circuit.

5. The welding-type power supply of claim 3 wherein the modulating control signals cause the first commutation switch and the second commutation switch to be off other than during commutation of current from at least one of the second switch and the first switch.

6. The welding-type power supply of claim 3, further comprising a commutation inductor disposed in at least one of the first freewheeling path and the second freewheeling path.

7. The welding-type power supply of claim 6, wherein the input circuit includes a rectifier.

8. The welding-type power supply of claim 6, wherein the commutation control module provides at least one of pulse width, pulse frequency and hysteretic modulating control signals to the commutation switch.

9. The welding-type power supply of claim 6, wherein the modulating control signals cause the first commutation switch and the commutation inductor to operate as a boost circuit to boost a voltage on an inverter dc bus to a desired magnitude when the first switch is on and not commutating.

10. The welding-type power supply of claim 9, wherein the modulating control signals cause the second commutation switch and the commutation inductor to operate as a second boost circuit to boost the voltage on the inverter dc bus to the desired magnitude when the second switch is on and not commutating.