Battery powered welder system utilizing vehicle powered AC inverter

• US 7,777,447 B2
• Filed: 03/29/2007
• Issued: 08/17/2010
• Est. Priority Date: 05/31/2006
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Vogel, Bernard J.
• Primary Examiner(s): Tso; Edward
• Assistant Examiner(s): DIAO, M BAYE
• Application Number:
  US11/729,469
• Publication Number:
  US 20070278993A1
• Time in Patent Office: 1,237 Days
• Field of Search: 320/107, 320/122, 320/126, 320/128, 320/140, 318/139, 318/801, 363/17, 363/98, 363/132, 219/130.4, 327/143
• US Class Current: 320/107
• CPC Class Codes: B23K 9/1081 Arc welding by means of accumulated energy
• CPC Class Codes: H02J 2207/40 adapted for charging from various sources, e.g. AC, DC or multivoltage
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/007 Regulation of charging or discharging current or voltage
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage

Abstract

A system and method, in certain embodiments, adjusts a charging output based on capabilities of various power sources. The system and method may be used to charge a variety of equipment such as welders, cutters, induction heaters, tools and so forth. For example, a charging circuit configured to change an output charge level based upon capabilities of multiple power sources configured to be coupled to the charging circuit. In some embodiments, the system and method may test the capabilities of the various power sources by evaluating an actual output versus a commanded output, and reduce the commanded output if the actual output falls below a desired level.

Claims

1. A system, comprising:

a charging circuit configured to change an output charge level based upon capabilities of multiple power sources configured to be coupled to the charging circuit;

a battery coupled to an output of the charging circuit; and

a cutting circuit, a welding circuit, an induction heating circuit, or a combination thereof, coupled to the battery;

wherein the charging circuit is configured to automatically detect the capabilities of a power source; and

wherein the charging circuit is configured to command an output of a sequence of pulses on the output of the charging circuit, each subsequent pulse comprising a power level greater than the power level of the preceding pulse, and the charging circuit is configured to detect the capabilities of the power source based on an actual power level sensed on the output of the charging circuit in response to the commanded pulses.

2. The system of claim 1, wherein the power sources comprise an AC power grid, or an AC inverter or both.

3. The system of claim 1, wherein the system is contained within a single housing.

4. The system of claim 3, wherein the system is portable.

5. The system of claim 1, comprising a switch comprising selectable positions configured to change the output charge level based on capabilities of the multiple power sources.

6. The system of claim 1, comprising a cord that is configured to couple the charging circuit to at least one power source of the multiple power sources and that comprises an identifying characteristic configured to identify the capabilities of the at least one power source.

7. A system, comprising:

a charging circuit configured to automatically detect capabilities of a power source coupled to the charging circuit and configured to automatically set a charging output level based on the capabilities of the power source;

wherein the charging circuit is configured to command generation of a sequence of pulses on an output of the charging circuit, each subsequent pulse comprising a power level greater than the power level of the preceding pulse, and the charging circuit is configured to automatically detect the capabilities of the power source based on an actual power level sensed on the output of the charging circuit in response to the commanded pulses.

8. The system of claim 7, comprising a welding circuit, a cutting circuit, an induction heating circuit, or a combination thereof coupled to the to the charging circuit.

9. The system of claim 7, comprising a battery coupled to the charging circuit.

10. The system of claim 7, wherein the power source comprises an AC power grid, an AC inverter or both.

11. The system of claim 7, wherein the charging circuit is configured to command generation of at least one pulse on an output of the charging circuit and that is configured to automatically detect the capabilities of the power source based on an actual power level sensed on the output of the charging circuit in response to the commanded pulse.

12. The system of claim 11, wherein the charging circuit is configured to set the charging output level at a reduced level if the actual power level sensed on the output is below a desired level.

13. The system of claim 7, wherein the charging circuit is configured to continue to command a sequence of pulses until an actual power level sensed on the output of the charging circuit is below a desired power level, and wherein the charging circuit is configured to set the charging output level at a level configured to enable the actual power output to remain at or above a desired power level.

14. The system of claim 7, wherein the charging circuit is configured to detect a capability of the power source to reset after the power source is overloaded, and to set the charging output level based on the capability of the power source to reset after the power source is overloaded.

15. A portable tool, comprising:

a battery;

an output coupled to the battery; and

a charging circuit coupled to the battery and configured to set a charging level based on an output capability of a plurality of different power sources;

wherein the charging circuit is configured to command generation of a sequence of pulses on an output of the charging circuit, each subsequent pulse comprises a power level greater than the power level of the preceding pulse, and the charging circuit is configured to automatically detect the capabilities of the power source based on an actual power level sensed on the output of the charging circuit in response to the commanded pulses.

16. The portable tool of claim 15, wherein the charging circuit is configured to automatically detect the output capability of a power source coupled to the charging circuit.

17. The portable tool of claim 15, wherein the charging circuit is configured to set the charging level at a reduced level if the actual power level generated on the output is below a desired level.

18. A method of charging, comprising:

automatically detecting capabilities of a power source, comprising;

commanding generation of a sequence of pulses on an output of a charging circuit coupled to the power source, each subsequent pulse comprising a power level greater than the power level of the preceding pulse;

sensing an actual power level generated on the output;

detecting a capability of the power source based on the actual power level sensed on the output of the charging circuit in response to the commanded pulses; and

automatically setting a charge level output of the charging circuit based on the capability detected.