Hybrid powered welder

• US 20060037953A1
• Filed: 08/17/2004
• Published: 02/23/2006
• Est. Priority Date: 08/17/2004
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Matthews, William T., Muter, Bryce, Stupczy, Frank M.
• Granted Patent: US 8,080,761 B2
• Time in Patent Office: Days
• US Class Current: 219/133
• CPC Class Codes: B23K 9/1006 Power supply
• 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: B23K 9/1081 Arc welding by means of accumulated energy

Abstract

An electric arc welder that includes a energy storage device and non-battery power source for the formation of an electric arc. The welder also includes battery charging circuit that controls the charging of the energy storage device by the non-battery power source. The non-battery power source can include an engine driven electric generator, power grid or a fuel cell.

Claims

1. An electric arc welder having a power source that creates an electric arc between an electrode and a workpiece, said power source including a energy storage device, a non-battery power source and an electric circuit, said electric circuit including a battery charging circuit that at least periodically directs current from said non-battery power source to said energy storage device during the operation of said non-battery power source, said electric circuit including a welding circuit that directs current from said energy storage device, said non-battery power source, or combination thereof to form said electric arc.

2. The electric arc welder as defined in claim 1, wherein said non-battery power source includes an engine driven electric generator, a fuel cell, solar cell, power grid or combination thereof.

3. The electric arc welder as defined in claim 1, wherein said battery charging circuit directs current from said non-battery power source to said energy storage device when an electric arc is not being formed between said electrode and workpiece.

4. The electric arc welder as defined in claim 2, wherein said battery charging circuit directs current from said non-battery power source to said energy storage device when an electric arc is not being formed between said electrode and workpiece.

5. The electric arc welder as defined in claim 1, wherein said energy storage device has an amp-hour rating to provide sufficient current to meet the maximum welding output rating of said electric arc welder for at least about one minute.

6. The electric arc welder as defined in claim 2, wherein said energy storage device has an amp-hour rating to provide sufficient current to meet the maximum welding output rating of said electric arc welder for at least about one minute.

7. The electric arc welder as defined in claim 4, wherein said energy storage device has an amp-hour rating to provide sufficient current to meet the maximum welding output rating of said electric arc welder for at least about one minute.

8. The electric arc welder as defined in claim 1, wherein said battery charging circuit includes an over charge circuit to prevent overcharging said energy storage device.

9. The electric arc welder as defined in claim 7, wherein said battery charging circuit includes an over charge circuit to prevent overcharging said energy storage device.

10. The electric arc welder as defined in claim 1, wherein said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

11. The electric arc welder as defined in claim 2, wherein said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

12. The electric arc welder as defined in claim 9, wherein said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

13. The electric arc welder as defined in claim 1, wherein said welding circuit includes a chopper circuit to control the waveform, current level or combinations thereof of the arc current.

14. The electric arc welder as defined in claim 2, wherein said welding circuit includes a chopper circuit to control the waveform, current level or combinations thereof of the arc current.

15. The electric arc welder as defined in claim 9, wherein said welding circuit includes a chopper circuit to control the waveform, current level or combinations thereof of the arc current.

16. The electric arc welder as defined in claim 1, wherein said electric circuit includes a selector that selects current from said energy storage device, non-battery power source, or combination thereof to supply current to said electric arc, said selector including a manual selector, an automatic selector, or combination thereof.

17. The electric arc welder as defined in claim 2, wherein said electric circuit includes a selector that selects current from said energy storage device, non-battery power source, or combination thereof to supply current to said electric arc, said selector including a manual selector, an automatic selector, or combination thereof.

18. The electric arc welder as defined in claim 12, wherein said electric circuit includes a selector that selects current from said energy storage device, non-battery power source, or combination thereof to supply current to said electric arc, said selector including a manual selector, an automatic selector, or combination thereof.

19. The electric arc welder as defined in claim 15, wherein said electric circuit includes a selector that selects current from said energy storage device, non-battery power source, or combination thereof to supply current to said electric arc, said selector including a manual selector, an automatic selector, or combination thereof.

20. The electric arc welder as defined in claim 1, including a wire feeder.

21. The electric arc welder as defined in claim 18, including a wire feeder.

22. The electric arc welder as defined in claim 19, including a wire feeder.

23. The electric arc welder as defined in claim 1, wherein said power source has a rating of at least about 100 amperes.

24. The electric arc welder as defined in claim 21, wherein said power source has a rating of at least about 100 amperes.

25. The electric arc welder as defined in claim 22, wherein said power source has a rating of at least about 100 amperes.

26. The electric arc welder as defined in claim 1, including an arc inhibitor that prevents formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

27. The electric arc welder as defined in claim 2, including an arc inhibitor that prevents formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

28. The electric arc welder as defined in claim 24, including an arc inhibitor that prevents formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

29. The electric arc welder as defined in claim 25, including an arc inhibitor that prevents formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

30. The electric arc welder as defined in claim 1, wherein said energy storage device includes a rechargeable battery, a capacitor, an inductor, a flywheel or combination thereof.

31. The electric arc welder as defined in claim 29, wherein said energy storage device includes a rechargeable battery, a capacitor, an inductor, a flywheel or combination thereof.

32. The electric arc welder as defined in claim 1, including a control system that obtains charge level information from said battery source and generates a signal to at least partially control said non-battery power source.

33. The electric arc welder as defined in claim 31, including a control system that obtains charge level information from said battery source and generates a signal to at least partially control said non-battery power source.

34. The electric arc welder as defined in claim 1, including an open circuit detector that obtains arc status information and generates a signal to at least partially control said welding circuit.

35. The electric arc welder as defined in claim 33, including an open circuit detector that obtains arc status information and generates a signal to at least partially control said welding circuit.

36. A method of forming an electric arc between an electrode and a workpiece comprising:

a. providing an electric arc welder that includes a power source, said power source including a energy storage device and a non-battery power source;

b. at least periodically charging said energy storage device from current generated from said non-battery power source; and

,

c. at least partially forming said electric arc from current from said energy storage device, said non-battery power source, or combination thereof to form said electric arc.

37. The method as defined in claim 36, wherein said non-battery power source includes an engine driven electric generator, a fuel cell, solar cell, power grid or combination thereof.

38. The method as defined in claim 36, including the step of forming said electric arc from current from said energy storage device and said non-battery power source.

39. The method as defined in claim 37, including the step of forming said electric arc from current from said energy storage device and said non-battery power source.

40. The method as defined in claim 36, including the step of at least partially charging said energy storage device by said non-battery power source when said non-battery source is generating a current and an electric arc is not being formed between said electrode and workpiece.

41. The method as defined in claim 37, including the step of at least partially charging said energy storage device by said non-battery power source when said non-battery source is generating a current and an electric arc is not being formed between said electrode and workpiece.

42. The method as defined in claim 38, including the step of at least partially charging said energy storage device by said non-battery power source when said non-battery source is generating a current and an electric arc is not being formed between said electrode and workpiece.

43. The method as defined in claim 39, including the step of at least partially charging said energy storage device by said non-battery power source when said non-battery source is generating a current and an electric arc is not being formed between said electrode and workpiece.

44. The method as defined in claim 36, including the step of selecting a power source to supply current to said electric arc.

45. The method as defined in claim 37, including the step of selecting a power source to supply current to said electric arc.

46. The method as defined in claim 42, including the step of selecting a power source to supply current to said electric arc.

47. The method as defined in claim 43, including the step of selecting a power source to supply current to said electric arc.

48. The method as defined in claim 36, including the step of providing an over charge circuit to prevent overcharging said energy storage device.

49. The method as defined in claim 37, including the step of providing an over charge circuit to prevent overcharging said energy storage device.

50. The method as defined in claim 47, including the step of providing an over charge circuit to prevent overcharging said energy storage device.

51. The method as defined in claim 36, wherein said energy storage device has an amp-hour rating to provide sufficient current to meet the maximum welding output rating of said electric arc welder for at least about one minute.

52. The method as defined in claim 50, wherein said energy storage device has an amp-hour rating to provide sufficient current to meet the maximum welding output rating of said electric arc welder for at least about one minute.

53. The method as defined in claim 36, including the step of providing a battery charging circuit, said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

54. The method as defined in claim 37, including the step of providing a battery charging circuit, said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

55. The method as defined in claim 45, including the step of providing a battery charging circuit, said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

56. The method as defined in claim 54, including the step of providing a battery charging circuit, said battery charging circuit includes a SCR phase angle control circuit and a rectifier to convert AC current to DC current for charging said energy storage device.

57. The method as defined in claim 36, including the step of providing a welding circuit to control the waveform, current level or combinations thereof of the arc current.

58. The method as defined in claim 37, including the step of providing a welding circuit to control the waveform, current level or combinations thereof of the arc current.

59. The method as defined in claim 46, including the step of providing a welding circuit to control the waveform, current level or combinations thereof of the arc current.

60. The method as defined in claim 52, including the step of providing a welding circuit to control the waveforrn, current level or combinations thereof of the arc current.

61. The method as defined in claim 36, including the step of providing a wire feeder.

62. The method as defined in claim 56, including the step of providing a wire feeder.

63. The method as defined in claim 60, including the step of providing a wire feeder.

64. The method as defined in claim 36, wherein said power source has a rating of at least about 100 amperes.

65. The method as defined in claim 62, wherein said power source has a rating of at least about 100 amperes.

66. The method as defined in claim 63, wherein said power source has a rating of at least about 100 amperes.

67. The method as defined in claim 36, including the step of inhibiting the formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

68. The method as defined in claim 65, including the step of inhibiting the formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

69. The method as defined in claim 66, including the step of inhibiting the formation of an electric arc between said electrode and said workpiece when a sensed power level of said battery power supply is below a preselected value.

70. The method as defined in claim 36, wherein said energy storage device includes a rechargeable battery, a capacitor, an inductor, a flywheel or combination thereof.

71. The method as defined in claim 69, wherein said energy storage device includes a rechargeable battery, a capacitor, an inductor, a flywheel or combination thereof.

72. The method as defined in claim 36, including the step of at least partially obtaining charge level information from said energy source device and at least partially controlling a charge rate of said energy source device.

73. The method as defined in claim 71, including the step of at least partially obtaining charge level information from said energy source device and at least partially controlling a charge rate of said energy source device.

74. The method as defined in claim 36, including the step of obtaining arc status information and at least partially controlling an operation of at least one component of said welder based on said arc status information.

75. The method as defined in claim 73, including the step of obtaining arc status information and at least partially controlling an operation of at least one component of said welder based on said arc status information.