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

• US 6,329,636 B1
• Filed: 03/31/2000
• Issued: 12/11/2001
• Est. Priority Date: 03/31/2000
• Status: Expired due to Term

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Geissler, Steven J.
• Primary Examiner(s): Shaw, Clifford C.
• Application Number:
  US09/540,567
• Time in Patent Office: 620 Days
• Field of Search: 219/137.PS, 219/130.1, 219/130.21, 219/130.31, 219/130.32, 219/130.33, 363/142
• US Class Current: 219/130.1
• CPC Class Codes: B23K 13/08 Electric supply or control circuits therefor
• CPC Class Codes: B23K 9/1006 Power supply
• CPC Class Codes: B23K 9/1043 characterised by the electric circuit B23K9/1012 takes precedence
• CPC Class Codes: B23K 9/1056 by using digital means B23K9/1068 takes precedence
• CPC Class Codes: B23K 9/1062 with computing means
• CPC Class Codes: H02M 1/0006 Arrangements for supplying an adequate voltage to the control circuit of converters
• 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 1/4208 Arrangements for improving power factor of AC input
• CPC Class Codes: Y02P 70/10 Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working

Abstract

A method and apparatus for providing welding type power 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, cutting or induction heating. The welding type current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and a controller power supply can also receive a range of input voltages and provide a control power signal to the controller, and a voltage independent of the input voltage.

Claims

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

an input circuit configured to receive an input power signal having an input frequency and an input magnitude and provide a first signal having a magnitude responsive to the input magnitude;

a preregulator configured to receive the first signal and provide a dc second signal having a preregulator magnitude independent of the input magnitude;

an output circuit configured to receive the dc second signal and provide a welding type output power signal having an output frequency independent of the input frequency and having an output voltage independent of the input voltage;

a preregulator controller, connected to the preregulator, and further having a controller power input; and

a control power circuit configured to receive the dc second signal and provide a control power signal to the controller power input, wherein the controller power signal has a control power magnitude independent of the input magnitude and a control frequency independent of the input frequency.

2. The apparatus of claim 1, wherein the input circuit includes a rectifier.

3. The apparatus of claim 1, wherein the preregulator magnitude is greater than the first magnitude.

4. The apparatus of claim 3, wherein the preregulator includes a boost converter.

5. The apparatus of claim 4, wherein the boost converter includes a slow voltage switched switch and a slow current switched switch.

6. The apparatus of claim 3, wherein the output circuit includes an inverter.

7. The apparatus of claim 3 wherein the output circuit includes a switched snubber.

8. The apparatus of claim 3, wherein the preregulator magnitude is greater than the control power magnitude.

9. The apparatus of claim 3 wherein the control power circuit includes a buck converter.

10. A welding type power source capable of receiving a range of input voltages and frequencies, comprising:

an input rectifier configured to receive an input power signal having an input frequency and an input magnitude and to provide a rectified signal having a rectified magnitude responsive to the input magnitude;

a slow voltage switched and slow current switched boost converter configured to receive the rectified signal and provide a boost dc signal having a boost magnitude greater than and independent of the rectified input magnitude;

an output circuit, including an inverter with a switched snubber, connected to receive the dc second signal and to provide a welding type power output having an output frequency independent of the input frequency and having an output voltage independent of the rectified magnitude;

a controller, connected to the converter and further having a controller power input; and

a control power circuit, including a buck converter connected to receive the boost dc signal and provide a control power signal to the controller power input, wherein the controller power signal has a control power magnitude less than and independent of the boost magnitude.

11. A method of providing welding type power from a range of input voltages and frequencies, comprising:

receiving an input power signal having an input frequency and an input magnitude;

providing a first signal having a magnitude responsive to the input magnitude;

converting the first signal into a dc second signal having a second magnitude independent of the input magnitude;

providing an output power signal derived from the dc second signal, wherein the output power signal is a welding type output and has an output frequency independent of the input frequency and further has an output voltage independent of the input voltage; and

converting the dc second signal into control power, wherein the control power has a control power magnitude independent of the input magnitude.

12. The method of claim 11, wherein providing a first signal includes rectifying an ac signal.

13. The method of claim 11, wherein the second magnitude is greater than the first magnitude.

14. The method of claim 13, wherein converting the first signal into a dc second signal includes boost converting the first signal.

15. The method of claim 13, wherein boost converting the first signal includes a slow voltage switching and slow current switching a switch.

16. The method of claim 13, wherein providing an output power signal includes inverting the dc second signal.

17. The method of claim 13 wherein inverting the dc second signal includes switching a snubber.

18. The method of claim 13, wherein the second magnitude is greater than the control power magnitude.

19. The method of claim 13 wherein converting the dc second signal into control power includes buck converting the dc second signal.

20. A method of providing welding type power from a range of input voltages and frequencies, comprising:

rectifying an input power signal having an input frequency and an input magnitude to provide a rectified signal having a rectified magnitude responsive to the input magnitude;

boost converting, including slow voltage switching and slow current switching, the rectified signal to provide a boost dc signal having a boost magnitude greater than and independent of the rectified input magnitude;

inverting, including switching a snubber, the dc second signal to provide a welding type power output having an output frequency independent of the input frequency and having an output voltage independent of the rectified magnitude; and

buck converting the boost dc signal to provide a control power signal, wherein the control power signal has a control power magnitude less than and independent of the boost magnitude, and a control frequency independent of the input frequency.

21. A welding type power source capable of receiving a range of input voltages and frequencies, comprising:

input means for receiving an input power signal having an input frequency and an input magnitude and for providing a first signal having a magnitude responsive to the input magnitude;

converting means for converting the first signal into a dc second signal having a magnitude independent of the input magnitude, wherein the converting means is connected to receive the first signal;

means for providing a welding type output power signal derived from the dc second signal, wherein the output power signal and has an output frequency independent of the input frequency and further has an output voltage independent of the input voltage, and wherein the means for providing an output power signal is disposed to receive the dc second signal;

means for converting the dc second signal into control power, wherein the control power has a control power magnitude independent of the input magnitude.

22. The apparatus of claim 21, wherein the first means includes means for rectifying an ac signal.

23. The apparatus of claim 22, wherein the convertor magnitude is greater than the first magnitude.

24. The apparatus of claim 23, wherein the converting means includes means for boost converting the first signal.

25. The apparatus of claim 24, wherein the means for boost converting includes means for slow voltage switching and slow current switching a switch.

26. The apparatus of claim 25, wherein the means for providing an output power signal includes means for inverting the dc second signal.

27. The apparatus of claim 26 wherein the means for inverting includes means for switching a snubber.

28. The apparatus of claim 27, wherein the converter magnitude is greater than the control power magnitude.

29. The apparatus of claim 28 wherein the means for converting the dc second signal into control power includes means for buck converting the dc second signal.

30. A welding type power source capable of receiving a range of input voltages and frequencies, comprising:

a dc bus;

an output circuit configured, having a control input and to receive the dc bus and provide a welding type output power signal having an output frequency independent of the input frequency and having an output voltage independent of the input voltage;

a controller, connected to the control input and further having a controller power input; and

a control power circuit configured to receive the dc bus and provide a control power signal to the controller power input.

31. The apparatus of claim 30, wherein the output circuit includes an inverter.

32. The apparatus of claim 31, wherein the output circuit includes a switched snubber.

33. The apparatus of claim 30, wherein the dc bus has a magnitude is greater than a magnitude of the control power signal.

34. The apparatus of claim 30 wherein the control power circuit includes a buck converter.

35. A method of providing welding type power from a range of input voltages and frequencies, comprising:

receiving a dc bus having a dc magnitude;

providing an output power signal derived from the dc bus, wherein the output power signal is a welding type output; and

converting the dc bus into control power, wherein the control power has a control power magnitude independent of the dc magnitude; and

providing the control power to a controller configured to control the output power.

36. A method of starting to provide welding type power from a range of input voltages and frequencies, comprising:

receiving an input power signal having an input frequency and an input magnitude;

providing a first dc signal having a first dc magnitude responsive to the input magnitude;

deriving a second dc voltage having a second dc magnitude less than the first dc magnitude controlling a control converter with the second dc voltage to produce a control dc voltage;

controlling an output converter with the control dc voltage to produce an output signal.