Power converter for engine generator

• US 8,922,034 B2
• Filed: 06/04/2013
• Issued: 12/30/2014
• Est. Priority Date: 07/27/2012
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Jochman, Nathan J.
• Primary Examiner(s): Cuevas, Pedro J
• Application Number:
  US13/910,067
• Publication Number:
  US 20140028029A1
• Time in Patent Office: 574 Days
• Field of Search: 290/1.A, 361/699, 361/818, 180/65.1
• US Class Current: 290/1.A
• CPC Class Codes: B23K 9/10 Other electric circuits therefor; Protective circuits; Remote controls
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R
• CPC Class Codes: G05F 1/02 Regulating electric characteristics of arcs arrangements for feeding electrodes B23K9/12, H05B7/109, H05B31/18; automatic control of power for heating by discharge H05B7/148
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• 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 1/42 Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
• CPC Class Codes: H02M 3/157 with digital control
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/2173 in a biphase or polyphase circuit arrangement H02M7/2176 takes precedence; voltage multipliers H02M7/25
• CPC Class Codes: H02P 9/00 Arrangements for controlling electric generators for the purpose of obtaining a desired output Ward-Leonard arrangements H02P7/34; vector control H02P21/00; feeding a network by two or more generators H02J; for charging batteries H02J7/14
• CPC Class Codes: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14322 wherein the control and power circuits of a power converter are arranged within the same casing
• CPC Class Codes: H05K 7/20 Modifications to facilitate cooling, ventilating, or heating
• CPC Class Codes: H05K 7/209 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20909 takes precedence

Abstract

A power converter for an engine generator includes an insulative support that receives and supports circuit components for converting incoming AC power to desired power, such as power suitable for a welding application. One or more rectifier modules are provided that are received and supported by the support. Three such modules may be provided for receiving three phase power from a generator. DC power from the rectifier module is applied to DC bus plates. The plates may be coupled to capacitors. A power conversion circuit, such as a buck converter, is coupled to the DC bus plates to convert the DC power to output power.

Claims

1. A power converter comprising:

an insulative support;

a rectifier module coupled to and supported by the insulative support, the rectifier module configured to receive AC power from a source;

plate-like DC bus elements disposed in the insulative support and separated from one another by an insulative plate, the DC bus elements receiving DC power from the rectifier module;

a power converter circuit supported by the insulative support and contacting the DC bus elements to receive the DC power and to convert the DC power to a desired output power; and

a drive circuit board supported by the insulative support and coupled to the power converter circuit to command operation of the power converter circuit during operation.

2. The power converter of claim 1, comprising three rectifier modules coupled to and supported by the insulative support for receiving and converting three phase AC power from the source to DC power for application to the DC bus elements.

3. The power converter of claim 1, comprising a capacitor supported by the insulative support and electrically coupled to the DC bus elements.

4. The power converter of claim 3, wherein the insulative support comprises a receptacle for receiving the capacitor, the receptacle fitting tightly around the capacitor for stabilizing the capacitor.

5. The power converter of claim 1, wherein the power converter circuit comprises a buck converter.

6. The power converter of claim 1, wherein the insulative support comprises upper and lower housings, the upper housing covering at least the DC bus elements and the drive circuit board.

7. The power converter of claim 1, wherein the insulative support receives and supports the rectifier module in a tongue-in-groove arrangement.

8. A power supply comprising:

an engine;

a generator couple to the engine and configured to generate AC power in operation; and

a power converter comprising an insulative support, a rectifier module coupled to and supported by the insulative support, the rectifier module configured to receive AC power from a generator, plate-like DC bus elements disposed in the insulative support and separated from one another by an insulative plate, the DC bus elements receiving DC power from the rectifier module, a power converter circuit supported by the insulative support and contacting the DC bus elements to receive the DC power and to convert the DC power to a desired output power, and a drive circuit board supported by the insulative support and coupled to the power converter circuit to command operation of the power converter circuit during operation.

9. The power supply of claim 8, comprising three rectifier modules coupled to and supported by the insulative support for receiving and converting three phase AC power from the generator to DC power for application to the DC bus elements.

10. The power supply of claim 8, comprising a capacitor supported by the insulative support and electrically coupled to the DC bus elements.

11. The power supply of claim 8, wherein the insulative support comprises a receptacle for receiving the capacitor, the receptacle fitting tightly around the capacitor for stabilizing the capacitor.

12. The power supply of claim 8, wherein the power converter circuit comprises a buck converter.

13. The power supply of claim 8, wherein the insulative support comprises upper and lower housings, the upper housing covering at least the DC bus elements and the drive circuit board.

14. The power supply of claim 8, wherein the insulative support receives and supports the rectifier module in a tongue-in-groove arrangement.

15. The power supply of claim 8, wherein the desired output power is suitable for a welding application.

16. A power supply comprising:

an engine;

a generator coupled to the engine and configured to generate AC power in operation, the generator configured to generate three phase power in operation; and

a power converter comprising an insulative support, three rectifier modules coupled to and supported by the insulative support, the rectifier modules configured to receive three phase AC power from a generator, plate-like DC bus elements disposed in the insulative support and separated from one another by an insulative plate, the DC bus elements receiving DC power from the rectifier module, a power converter circuit supported by the insulative support and contacting the DC bus elements to receive the DC power and to convert the DC power to a output power suitable for a welding application, and a drive circuit board supported by the insulative support and coupled to the power converter circuit to command operation of the power converter circuit during operation.

17. The power supply of claim 16, comprising a capacitor supported by the insulative support and electrically coupled to the DC bus elements.

18. The power supply of claim 17, wherein the insulative support comprises a receptacle for receiving the capacitor, the receptacle fitting tightly around the capacitor for stabilizing the capacitor.

19. The power supply of claim 16, wherein the power converter circuit comprises a buck converter.

20. The power supply of claim 16, wherein the insulative support comprises upper and lower housings, the upper housing covering at least the DC bus elements and the drive circuit board.