Welding system having a power grid interface

• US 9,089,922 B2
• Filed: 01/21/2011
• Issued: 07/28/2015
• Est. Priority Date: 01/22/2010
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Bunker, Thomas A., Albrecht, Bruce Patrick
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): LAFLAME JR, MICHAEL A
• Application Number:
  US13/011,586
• Publication Number:
  US 20110180522A1
• Time in Patent Office: 1,649 Days
• Field of Search: 219120-129, 219130-139
• US Class Current: 1/1
• 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 9/1075 Parallel power supply, i.e. multiple power supplies or multiple inverters supplying a single arc or welding current

Abstract

Welding system and method permit exchange of data with Smart Grid monitors and/or controllers. The welding systems include a welding power supply configured to convert power between the power grid and the welding power supply. A grid interface cooperates with control circuitry to transmit data to and/or from the grid monitors and/or controllers on the grid side. The control circuitry may control operation of the welding power supply based upon data from the grid. The system may include power generation devices (e.g., engine-drive generators) and energy storage devices (e.g., batteries). The control circuitry may control operation of such devices, the exchange of power between them, and the draw of power from the grid or the application of power to the grid based upon the data exchanged with the grid monitors and/or controllers.

Claims

1. A welding system comprising:

a welding power supply comprising power conversion circuitry configured to receive power from a power grid and to convert the power received from the power grid to welding power suitable for a welding operation, wherein the welding power supply comprises;

a power generation device configured to produce electrical power for the welding operation;

a grid interface configured to communicate data to a grid-side monitor or controller in one or more components of an energy producer or distributor and to receive data from the grid-side monitor or controller; and

control circuitry coupled to the grid interface and configured to control operation of the power conversion circuitry based at least partially upon the data received from the grid-side monitor or controller, wherein the control circuitry is configured to command the welding power supply to apply generated or stored power from the power generation device to the power grid based at least partially upon data received from the grid-side monitor or controller.

2. The welding system of claim 1, wherein the grid interface is configured to transmit data relating to operation of the welding power supply to the grid-side monitor or controller.

3. The welding system of claim 1, wherein the power generation device comprises an engine-generator.

4. The welding system of claim 1, wherein the control circuitry is configured to alternatively command the welding power supply to draw power only from the power generation device or only from the power grid based at least partially upon data received from the grid-side monitor or controller.

5. The welding system of claim 1, wherein the welding power supply comprises an energy storage device configured to store energy for use by the welding operation, and wherein the control circuitry is configured to control charging of the energy storage device, discharging of the energy storage device, or both, based at least partially upon data received from the grid-side monitor or controller.

6. The welding system of claim 5, wherein the control circuitry is configured to alternatively command the welding power supply to draw power only from the power generation device and the energy storage device or only from the power grid based at least partially upon data received from the grid-side monitor or controller.

7. The welding system of claim 1, wherein the grid interface is configured to transmit the data to the grid-side monitor or controller or to receive the data from the grid-side monitor or controller during an arc welding operation.

17. The welding system of claim 1, wherein the data communicated to the grid-side monitor or controller comprises power-related data.

18. The welding system of claim 17, wherein the power-related data corresponds to a power need of the welding power supply, power utilization by the welding power supply, or a combination thereof.

19. The welding system of claim 1, wherein the data received from the grid-side monitor or controller comprises power-related data.

20. The welding system of claim 19, wherein the power-related data corresponds to past power demand, present power demand, power availability, power factor related information, power pricing, or a combination thereof.

21. The welding system of claim 1, wherein the control circuitry is configured to control operation of the power conversion circuitry based at least partially upon operator selection of weld settings received via an operator interface.

8. A welding system comprising:

a welding power supply comprising power conversion circuitry configured to receive power from a power grid and to convert the power received from the power grid to welding power suitable for a welding operation, wherein the welding power supply comprises;

a grid interface configured to communicate data to a grid-side monitor or controller in one or more components of an energy producer or distributor and to receive data from the grid-side monitor or controller;

at least one of a power generation device configured to produce electrical power for the welding operation or an energy storage device configured to store energy for use by the welding operation; and

control circuitry coupled to the grid interface and to the at least one of the power generation device or the energy storage device, and configured to control operation of the power conversion circuitry and the at least one of the power generation device or the energy storage device based at least partially upon the data received from the grid-side monitor or controller, wherein the control circuitry is configured to command the welding power supply to apply generated or stored power from the at least one power generation device or the energy storage device to the power grid based at least partially upon data received from the grid-side monitor or controller.

9. The welding system of claim 8, wherein the control circuitry is configured to command exchange of electrical power between the power conversion circuitry, the power generation device, and the energy storage device.

10. The welding system of claim 8, wherein the grid interface is configured to transmit data relating to operation of the welding power supply to the grid-side monitor or controller.

11. The welding system of claim 10, wherein the grid interface is configured to transmit the data to the grid-side monitor or controller or to receive the data from the grid-side monitor or controller during an arc welding operation.

22. The welding system of claim 8, wherein the data communicated to the grid-side monitor or controller comprises power-related data.

23. The welding system of claim 22, wherein the power-related data corresponds to a power need of the welding power supply, power utilization by the welding power supply, the electrical power produced by the power generation device, the energy stored by the energy storage device, or a combination thereof.

24. The welding system of claim 8, wherein the data received from the grid-side monitor or controller comprises power-related data.

25. The welding system of claim 24, wherein the power-related data corresponds to past power demand, present power demand, power availability, power factor related information, power pricing, or a combination thereof.

26. The welding system of claim 8, wherein the control circuitry is configured to control operation of the power conversion circuitry based at least partially upon operator selection of weld settings received via an operator interface.

12. A welding system comprising:

a welding power supply comprising power conversion circuitry configured to receive power from a power grid and to convert the power received from the power grid to welding power suitable for a welding operation, wherein the welding power supply comprises;

a grid interface configured to communicate data to a grid-side monitor or controller in one or more components of an energy producer or distributor and to receive data from the grid-side monitor or controller;

a power generation device configured to produce electrical power for the welding operation and an energy storage device configured to store energy for use by the welding operation; and

control circuitry coupled to the grid interface, to the power generation device, and to the energy storage device, and configured to control operation of the power conversion circuitry, the power generation device, and the energy storage device based at least partially upon the data received from the grid-side monitor or controller, wherein the control circuitry is configured to command the welding power supply to apply generated or stored power from the power generation device or the energy storage device to the power grid based at least partially upon data received from the grid-side monitor or controller.

13. The welding system of claim 12, wherein the control circuitry is configured to command exchange of electrical power between the power conversion circuitry, the power generation device, and the energy storage device.

14. The welding system of claim 12, wherein the grid interface is configured to transmit data relating to operation of the welding power supply to the grid-side monitor or controller.

15. The welding system of claim 14, wherein the grid interface is configured to transmit the data to the grid-side monitor or controller or to receive the data from the grid-side monitor or controller during an arc welding operation.

16. The welding system of claim 12, wherein the control circuitry is configured to command the welding power supply to apply generated power from the welding power supply to the power grid based at least partially upon data received from the grid-side monitor or controller.

27. The welding system of claim 12, wherein the data communicated to the grid-side monitor or controller comprises power-related data.

28. The welding system of claim 27, wherein the power-related data corresponds to a power need of the welding power supply, power utilization by the welding power supply, anticipated power needs, the electrical power produced by the power generation device, the energy stored by the energy storage device, or a combination thereof.

29. The welding system of claim 12, wherein the data received from the grid-side monitor or controller comprises power-related data.

30. The welding system of claim 29, wherein the power-related data corresponds to past power demand, present power demand, power availability, power factor related information, power pricing, or a combination thereof.

31. The welding system of claim 12, wherein the control circuitry is configured to control operation of the power conversion circuitry based at least partially upon operator selection of weld settings received via an operator interface.