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Constant-speed motor-driven modular welding apparatus with electronic power control apparatus, electrode holder operation controls, and safety interlock

  • US 6,512,199 B1
  • Filed: 12/20/1999
  • Issued: 01/28/2003
  • Est. Priority Date: 12/20/1999
  • Status: Active Grant
First Claim
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1. A motor driven, modular, constant current DC (Direct Current) arc welding apparatus with Electronic Power Control Apparatus, Remote Operator Control Apparatus, and Safety Interlock comprising:

  • A. a single drive motor capable of driving one, or more than one, high current alternator, operating at a constant speed when welding power is being produced;

    B. single, or multiple, electrically inter-connectable, forced-air or water cooled, power generating alternator modules each of which consists of a rotating electromagnet means which is coupled to, and driven by, said drive motor, producing a rotating magnetic field and generating a three (3) phase alternating current in response to the relative rotation of this magnetic field within a plurality of interconnected stationary coil windings wound around an armature;

    C. a full-wave rectifier means, which may be located either internally or externally, for each power generating alternator module, used for converting the three (3) phase alternating current produced by said stationary coil windings into a direct current for welding, and which also serves to electrically isolate interconnected power generating alternator modules;

    D. an electrical cable means used to connect the positive and negative DC outputs of each said full-wave rectifier means to a welding electrode and a grounding connector;

    E. an electronic power control apparatus wherein a direct current pulse-width modulation means is generated and used to supply, and to control, the current flowing through the rotating electromagnet of one, or multiple, power generating alternator modules; and

    F. a combination electrode holder/welder control apparatus which locates operator controls, on or within, a welding electrode holder, positioned so that all controls can be operated, without fatigue or undue strain, with whatever hand, left or right, by which the operator may be griping said electrode holder and where said operator controls are comprised of a potentiometer and two momentary contact push-buttons;

    1) wherein said potentiometer provides a means for instantaneously controlling and adjusting the duty cycle of said pulse width modulation means located within the electronic power control apparatus and, thereby, the welding current produced by said power generating alternator modules, which can be operated at any time, even while welding, and 2) wherein one push-button provides a means to override and replace the welding power setting determined by the position of said potentiometer, thereby providing a means for allowing an operator to instantaneously increase the current produced by the power generating alternator modules to facilitate starting a welding arc when difficult conditions are encountered and then, by releasing the push-button means, to return the power generating alternator module, or modules, instantaneously to the power setting previously determined by the potentiometer; and

    3) wherein the second push-button provides a means for instantly activating or deactivating the electronic power control apparatus and, therefore, the power generating alternator module, or modules, thereby addressing three critical design elements by providing a means for;

    a) switching said power generating alternator modules, or modules, on and off, and b) an operator safety interlock, by insuring that said power generating alternator module, or modules, are only activated when, and while, an operator maintains the activation of said push-button, and c) greatly limiting the production of excessive, and potentially damaging;

    waste heat within said stationary coil windings, which otherwise occurs whenever operating the power generating alternator module, or modules, without an electrical load. G. an electrical interconnection means whereby electrical signals produced by said combination electrode holder/welder control are transmitted to said electronic power control means either;

    1) by a control cable means which is combined with said electrical cable means used to carry power from the power generating alternator module, or modules, to the welding electrode holder, or 2) directly by a wireless transmission means.

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