MULTIPLE WELDING USING A SINGLE POWER SOURCE

• US 20080083705A1
• Filed: 10/05/2006
• Published: 04/10/2008
• Est. Priority Date: 10/05/2006
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Peters, Steven R.
• Granted Patent: US 8,946,596 B2
• Time in Patent Office: Days
• US Class Current: 219/61
• CPC Class Codes: B23K 9/091 characterised by the circuits
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: B23K 9/1062 with computing means
• CPC Class Codes: B23K 9/1068 Electric circuits for the supply of power to two or more arcs from a single source

Abstract

Welding systems are presented, in which a single power source provides a first DC output to a plurality of digital waveform controlled chopper modules. Welding modules are also disclosed for converting an input DC signal to a welding signal, which are comprised of a down-chopper for providing a welding signal waveform according to a pulse width modulated switching signal, along with a digital waveform controller providing the switching signal according to a desired waveform.

Claims

1. A welding system, comprising:

a power source receiving AC input power and providing a first DC output signal;

a first welding module coupled with said power source, said first welding module comprising;

a first down-chopper receiving said first DC output signal and providing a first electrical welding signal waveform comprising a rapid succession of individual pulses that define said first waveform to establish a first welding arc in a first welding process according to a pulse width modulated first switching signal, and

a first digital waveform controller providing said pulse width modulated first switching signal according to a desired first waveform; and

a second welding module coupled with said power source, said second welding module comprising;

a second down-chopper receiving said first DC output signal and providing a second electrical welding signal waveform comprising a rapid succession of individual pulses that define said second waveform to establish a second welding arc in a second welding process according to a pulse width modulated second switching signal, and

a second digital waveform controller providing said pulse width modulated second switching signal according to a desired second waveform.

4. A welding system as defined in claim 1, further comprising a synchronizing controller adapted to synchronize said first and second digital waveform controllers.

5. A welding system as defined in claim 4, wherein said synchronizing controller is integrated into said first welding module.

6. A welding system as defined in claim 1, wherein said DC-DC switching converters each have a maximum rated output current of about 300 amps or more.

7. A welding system as defined in claim 1, wherein said welding modules each weigh about 100 pounds or less.

8. A welding system, comprising:

a power source with a positive output terminal, a negative output terminal, and a ground terminal, said power source providing a DC output signal at said output terminals with a voltage of said positive output terminal being higher than a voltage of said ground terminal and with said voltage of said ground terminal being between said voltage of said positive output terminal and a voltage of said negative output terminal;

a first down-chopper coupled to said positive output terminal, said first down-chopper providing a first electrical welding signal waveform comprising a rapid succession of individual pulses that define said first waveform in a welding process according to a pulse width modulated first switching signal;

a first digital waveform controller providing said pulse width modulated first switching signal according to a desired first waveform;

a second down-chopper coupled to said negative output terminal, said second down-chopper providing a second electrical welding signal waveform comprising a rapid succession of individual pulses that define said second waveform in said welding process according to a pulse width modulated second switching signal;

a second digital waveform controller providing said pulse width modulated second switching signal according to a desired second waveform; and

a synchronizing controller adapted to synchronize said first and second digital waveform controllers.

9. A welding system as defined in claim 8, wherein said first down-chopper and said first digital waveform controller are integrated into a first welding module, and wherein said second down-chopper and said second digital waveform controller are integrated into a second welding module.

10. A welding system as defined in claim 9, wherein said synchronizing controller is integrated into one of said welding modules.

11. A welding system as defined in claim 8, wherein said down-choppers each have a rated maximum output current rating of about 300 amps or more.

12. A welding system as defined in claim 8, wherein said welding modules each weigh about 100 pounds or less.

13. A welding system as defined in claim 8, wherein said first and second down-choppers, said first and second digital waveform controllers, and said synchronizing controller are integrated into a welding module.

14. A welding chopper module for converting an input DC signal to a welding signal for performing a welding process, said welding module comprising:

a first down-chopper having an input for receiving a DC signal from an external power source, and a switching circuit for providing a first electrical welding signal waveform comprising a rapid succession of individual pulses that define said first waveform in a welding process according to a pulse width modulated first switching signal; and

a first digital waveform controller integrated with said first down-chopper and providing said pulse width modulated first switching signal according to a desired first waveform wherein said chopper module receives only power and outputs a current suitable for welding.

2. A system as defined in claim 17 further comprising a short circuit welding control module coupled to receive said first electrical welding signal waveform from said first welding module, said short circuit welding control module comprising:

means for sensing an anticipated metal breaking fuse condition in said first welding process; and

means for selectively reducing current to said first welding process according to said anticipated fuse condition.

3. A welding system as defined in claim 2, further comprising:

a polarity switching system coupled to receive said first electrical welding signal waveform from said first welding module, said polarity switching system comprising;

switching means operative in a first state to provide current of a first polarity from said first electrical signal to said first welding process and in a second state to provide current of a second opposite polarity from said first electrical signal to said first welding process; and

a polarity controller providing a polarity signal to said switching means to selectively place said switching means in one of said first and second states.

15. A welding module as defined in claim 14, further comprising a synchronizing controller adapted to synchronize said first digital waveform controller with another digital waveform controller.

16. A welding module as defined in claim 14, wherein said down-chopper has a maximum rated output current of about 300 amps or more.

17. A welding module as defined in claim 14, wherein said welding module weighs about 100 pounds or less.

18. A welding module as defined in claim 15, further comprising:

a second down-chopper having an input for receiving a DC signal from an external power source, and a switching circuit for providing a second electrical welding signal waveform comprising a rapid succession of individual pulses that define said second waveform in a welding process according to a pulse width modulated second switching signal; and

a second digital waveform controller providing said pulse width modulated second switching signal according to a desired second waveform;

wherein said synchronizing controller is adapted to synchronize said first and second digital waveform controllers.

19. A welding module as defined in claim 14, further comprising:

a second down-chopper having an input for receiving a DC signal from an external power source, and a switching circuit for providing a second electrical welding signal waveform comprising a rapid succession of individual pulses that define said second waveform in a welding process according to a pulse width modulated second switching signal; and

a second digital waveform controller providing said pulse width modulated second switching signal according to a desired second waveform.

20. A welding module as defined in claim 14, further comprising a polarity switching system coupled to receive said first electrical welding signal waveform from said switching circuit, said polarity switching system comprising:

switching means operative in a first state to provide current of a first polarity from said first electrical signal to said first welding process and in a second state to provide current of a second opposite polarity from said first electrical signal to said first welding process; and

a polarity controller providing a polarity signal to said switching means to selectively place said switching means in one of said first and second states.

21. A welding module as defined in claim 14, further comprising a short circuit welding control module coupled to receive said first electrical welding signal waveform from said switching circuit, said short circuit welding control module comprising:

means for sensing an anticipated metal breaking fuse condition in said first welding process; and

means for selectively reducing current to said first welding process according to said anticipated fuse condition.

22. A welding module as defined in claim 14, wherein said first digital waveform controller is programmable.