Power supply assembly for a plasma arc torch system

• US 9,550,251 B2
• Filed: 03/28/2014
• Issued: 01/24/2017
• Est. Priority Date: 03/28/2014
• Status: Active Grant

• Current Assignee: Hypertherm Incorporated
• Original Assignee: Hypertherm Incorporated
• Inventors: Gullotta, Justin
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US14/228,592
• Publication Number:
  US 20150273617A1
• Time in Patent Office: 1,033 Days
• Field of Search: 219/121.54, 219/121.57, 219/121.48
• US Class Current: 1/1
• CPC Class Codes: B23K 10/006 Control circuits therefor circuits for plasma torches H05H1/36
• CPC Class Codes: H05H 1/36 Circuit arrangements H05H1/38, H05H1/40 take precedence

Abstract

A power supply assembly for a plasma arc torch is provided. The power supply assembly includes an input circuit, an energy storage device, a torch connector and an output circuit. The input circuit is configured to produce a first output signal. The energy storage device is electrically connected to the input circuit for receiving a charge signal therefrom. The energy storage device is capable of producing a second output signal. The torch connector is electrically connected to the input circuit and the energy storage device for receiving the first and second output signals through the output circuit. The torch connector is configured to supply at least one of the first or second output signal to the plasma arc torch to sustain a plasma arc.

Claims

1. A power supply assembly for a plasma arc torch, the power supply assembly comprising:

an input circuit configured to produce a first output signal, the input circuit including at least one of a boost circuit or a rectification circuit;

an energy storage device electrically connected to an output of the input circuit for receiving a charge signal from the input circuit, the energy storage device configured to produce a second output signal; and

a torch connector electrically connected to the input circuit and the energy storage device for receiving the first and second output signals, wherein the torch connector is configured to supply the first output signal, the second output signal, or a combination of the first and second output signals to the plasma arc torch to sustain a plasma arc based on comparing a parameter of the plasma arc torch with at least one of the first or second output signal.

2. The power supply assembly of claim 1, further comprising an inverter circuit configured to convert the at least one of the first or second output signal from a direct current (DC) format to an alternating current (AC) format prior to delivering the signal to the plasma arc torch.

3. The power supply assembly of claim 1, wherein the plasma arc torch comprises an air-cooled plasma arc torch.

4. The power supply assembly of claim 1, wherein the boost circuit is a boost circuit for the plasma arc torch.

5. The power supply assembly of claim 1, wherein the rectification circuit is a rectification circuit for the plasma arc torch.

6. The power supply assembly of claim 1, wherein at least one of the boost circuit or the rectification circuit is configured to supply power to the plasma arc torch system.

7. The power supply assembly of claim 1, further comprising power management circuitry disposed in the input circuit to manage transfer of energy from the input circuit to the energy storage device via the charge signal.

8. The power assembly of claim 1, wherein the plasma arc torch is operated using power supplied, at least in part, from the energy storage device.

9. The power supply assembly of claim 1, wherein the plasma arc torch is operated using power supplied substantially from the input circuit.

10. A method for operating a power supply assembly for supplying power to a plasma arc torch system, the method comprising:

directing an input signal to an input circuit to produce a first output signal, wherein the input circuit is configured to perform at least one of boosting a voltage of the input signal or rectifying a current of the input signal;

receiving, by an energy storage device electrically connected to an output of the input circuit, a charge signal from the input circuit;

generating, by the energy storage device, a second output signal configured to supplement the first output signal;

comparing a parameter of the plasma arc torch system with at least one of the first or second output signal; and

delivering directly, by a torch connector, the first output signal, the second output signal, or a combination of the first and second output signals to the plasma arc torch system based on the comparing to sustain a plasma arc.

11. The method of claim 10, further comprising sustaining the plasma arc by energy substantially from the second output signal of the energy storage device.

12. The method of claim 10, further comprising sustaining the plasma arc by energy from both the input circuit and the energy storage device.

13. The method of claim 10, further comprising sustaining the plasma arc by energy substantially from the first output signal of the input circuit.

14. The method of claim 10, further comprising:

monitoring a parameter associated with the plasma arc torch system; and

determining, based on the monitoring, an amount of power for delivery by the second output signal of the energy storage device to supplement the power of the first output signal.

15. The method of claim 14, further comprising increasing the amount of power delivered by the second output signal in response to a decrease or disappearance in the power of the first output signal.

16. The method of claim 10, further comprising modifying, by an inverter circuit, the at least one first or second output signal from a DC waveform to an AC waveform, wherein the inverter circuit is electrically connected to the energy storage device and the input circuit.

17. The method of claim 16, further comprising supplying, by the inverter circuit, the modified first or second output signal to the plasma arc torch system via the torch connector.

18. The method of claim 12, further comprising operating the plasma arc torch system to perform a cutting operation using the energy from both the input circuit and the energy storage device.

19. The method of claim 18, further comprising transitioning the cutting operation to substantially rely on the energy from the second output signal of the energy storage device.

20. The method of claim 18, further comprising transitioning the cutting operation to substantially rely on the energy from the first output signal of the input circuit.

21. The method of claim 10, further comprising modifying the at least one first or second output signal by an inverter circuit electrically connected to the energy storage device and the input circuit.

22. The method of claim 10, wherein the nominal voltage of the at least one the first output signal or the second output signal remains constant regardless of the voltage of the input signal.