Method and apparatus for receiving a universal input voltage in a welding power source

• US 5,601,741 A
• Filed: 11/18/1994
• Issued: 02/11/1997
• Est. Priority Date: 11/18/1994
• Status: Expired due to Term

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Thommes, James M.
• Primary Examiner(s): Shaw, Clifford C.
• Application Number:
  US08/342,378
• Time in Patent Office: 816 Days
• Field of Search: 219/130.21, 219/130.1, 219/130.51, 219/137 PS, 363/142, 363/143
• US Class Current: 219/137.0PS
• CPC Class Codes: B23H 7/08 Wire electrodes
• CPC Class Codes: B23K 9/0953 using computing means
• 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 5/458 using semiconductor devices only

Abstract

A method and apparatus for providing a welding current is disclosed. The power source is capable of receiving any input voltage over a wide range of input voltages and includes an input rectifier that rectifies the ac input into a dc signal. A dc voltage stage converts the dc signal to a desired dc voltage and an inverter inverts the dc signal into a second ac signal. An output transformer receives the second ac signal and provides a third ac signal that has a current magnitude suitable for welding. The welding current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and an auxiliary power controller that can receive a range of input voltages and provide a control power signal to the controller.

Claims

1. A welding power source capable of receiving a range of input voltages, comprising:

an input rectifier configured to receive any input voltage within the range of input voltages, and configured to provide a first dc signal;

a dc voltage stage configured to receive the first dc signal and providing a second dc signal;

an inverter configured to receive the second dc signal and providing a second ac signal and configured to receive at least one control input;

an output transformer configured to receive the second ac signal and providing a third ac signal having a current suitable for welding;

an output circuit configured to receive the third ac signal and providing a welding signal;

a controller configured to provide at least one control signal to the inverter; and

an auxiliary power source configured to receive any voltage within a range of auxiliary input voltages and configured to provide a control power signal to the controller.

2. The apparatus of claim 1, wherein the auxiliary power controller is capable of providing the control power signal at a preselected control signal voltage, regardless of the magnitude of the ac input signal.

3. The apparatus of claim 2, further including an auxiliary transformer with a plurality of primary taps, wherein the auxiliary power controller is in electrical communication with the plurality of primary taps.

4. The apparatus of claim 1, wherein the dc voltage stage includes a boost circuit.

5. The apparatus of claim 1, wherein the inverter includes a pulse width modulator.

6. The apparatus of claim 1, wherein the range of input voltages is 230 volts to 575 volts.

7. The apparatus of claim 1 wherein the output circuit includes a rectifier.

8. The apparatus of claim 1 wherein the output circuit includes a cycloconverter.

9. A method of providing a welding current from a range of input voltages, comprising:

rectifying any ac voltage within the range and providing a first dc signal;

converting the dc signal to a second ac signal; and

transforming the second ac signal into a third ac signal having a current suitable for welding; and

receiving the any ac voltage and providing an auxiliary power signal source at a preselected control power signal voltage, regardless of the magnitude of the ac input signal.

10. The method of claim 9, wherein the step of converting the dc signal includes the steps of converting the dc signal to a second dc signal and inverting the second dc signal to provide the second ac signal.

11. The method of claim 10, wherein the step of converting the first dc signal to a second dc signal includes boosting the voltage of the first dc signal.

12. The method of claim 10, wherein the step of inverting includes the step of pulse width modulating.

13. The method of claim 10 further including the step of rectifying the third ac signal.

14. The method of claim 10 further includes the step of cycloconverting the third ac signal.

15. The method of claim 9 further including the step of providing control signals to an inverter.

16. The method of claim 9, wherein the step of providing the auxiliary power signal includes the step of transforming the ac input signal.

17. A welding power source for providing a welding current from a range of input voltages, comprising:

rectifier means for receiving any voltage within the range and providing a first dc signal;

converting means for converting the dc signal to a second ac signal; and

transforming means for transforming the second ac signal into a third ac signal having a current suitable for welding;

output means for providing a welding current; and

auxiliary power means for receiving an auxiliary input voltage and providing an auxiliary power signal source at a preselected control power signal voltage, regardless of the magnitude of the auxiliary input voltage.

18. The apparatus of claim 17, wherein the means for converting includes means for converting the dc signal to a second dc signal and means for inverting the second dc signal to provide the second ac signal.

19. The apparatus of claim 17 further including means for providing control signals to an inverter.

20. The apparatus of claim 17, wherein the means for providing the auxiliary power signal includes means for transforming the ac input signal into the auxiliary power signal.

21. The apparatus of claim 17, wherein the means for converting the dc signal to a second dc signal includes means for boosting the voltage.

22. The apparatus of claim 17, wherein the means for inverting includes means for pulse width modulating.

23. The apparatus of claim 17, wherein the output means includes means for rectifying the third ac signal.

24. The apparatus of claim 17, wherein the output means includes means for cycloconverting the third ac signal.