Illinois Tool Works Inc.

Adam E Anders

Bernard J Vogel

Brian Schwartz

Andrew David Nelson

Erik Miller

Shuang Liu

Dennis Roland Sigl

Brian Doyle

Richard Martin Hutchison

Quinn William Schartner

Paul William Garvey

Mark Richard Christopher

Maxwell Bode Brock

Caleb M Rosera

Bo Zhang

James T Olejniczak

Randy Decoster

Daniel J Mortensen

Systems and methods are disclosed for integrated compressed air cooling for welding systems. In particular, the disclosed systems and methods may employ compressed air to implement one or more welding processes (e.g., a gouging or cutting processes), with the compressed air being conveyed through such welding systems. In some examples, the compressed air is routed within the welding system to provide cooling for one or more components therein. For instance, components such as power conversion circuitry may heat up during the welding process. Routing compressed air to or near the components will introduce relatively cool air to the environment. As the passing compressed air heats in response to interaction with the heated components, heat is drawn from the components and/or the nearby environment.

Integrated compressed air cooling for welding systems

A method and apparatus for controlling arc/short between a wire and a work piece is described. A current path parallel to the wire/work is provided. The voltage drop across the parallel path can be preset, to limit the wire/work voltage, or it can be controlled to a desired level. The control can be in response to feedback.

Welding system with arc control

Apparatus, systems, and/or methods are disclosed relating to a welding-type power supply with a pre-regulator circuit configured to provide a pre-regulated direct current (DC) bus at two or more voltage levels, responsive to various operating conditions. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus voltage at one voltage level for certain input line voltages, weld processes, and/or target weld output levels, and at another voltage level for other input line voltages, weld processes, and/or target weld output levels. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus voltage for certain input line voltages, weld processes, and/or target weld output levels and an unregulated DC bus voltage at other input line voltages, weld processes, and/or target weld output levels. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus at a service voltage in response to detecting a service mode of operation, and/or at an idle voltage in response to detecting an idle mode of operation.

Systems, methods, and apparatus for pre- regulator control in welding-type power supplies

A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

Methods for welding with a power supply with output rectifier and phase shift double forward converter

A welding-type system includes a power supply configured to control preheating of an electrode wire. A controller is configured to receive a plurality of power values corresponding to a power output of the power supply and calculate an arc power value corresponding to an arc condition at the preheated electrode wire based on a rate of change of the plurality of power values. A target power output value is determined based on the calculated arc power value, and the power output is adjusted based on the determined target power value.

Systems and methods for adaptive control of wire preheating

Disclosed are apparatus and systems to determine voltage measurements in welding-type applications to facilitate control of welding-type processes. Disclosed systems include a remote operations interface configured to facilitate voltage measurements in welding-type applications and facilitate communication between a welding-type power supply and a wire feeder.

Apparatus and systems to determine voltage measurements in welding-type applications

Welding power supplies, wire feeders, and systems to measure a weld circuit resistance via communications over the weld circuit are disclosed. An example welding-type power supply includes: a power conversion circuitry configured to: convert input power to output a signal via a weld circuit; and convert the input power to output welding-type power via the weld circuit; a voltage monitor configured to measure a power supply output voltage of the signal; communications circuitry configured to receive, via the weld circuit, a communication of a second voltage measurement; and control circuitry configured to: determine a resistance and/or and inductance of a portion of the weld circuit based on the power supply output voltage measurement, the second voltage measurement, and a weld circuit current.

Welding power supplies, wire feeders, and systems to measure a weld cable impedance

Systems, methods, and apparatus for pre-regulator control in welding-type power supplies

A welding-type power supply including a balanced plate rectifier to rectify high frequency alternating current from one or more transformers. The balanced plate rectifier includes an output terminal symmetrically connected to the plates of the plate rectifiers. The impedance between the output terminal and each plate is substantially equal.

Balanced plate rectifiers and welding-type power supplies including balanced plate rectifiers

Welding power supplies, wire feeders, and systems to measure a weld cable voltage drop are disclosed. Example welding-type power supplies include a power converter configured to convert input power to output welding-type power to a remote device via a weld cable; a reference conductor connected between the power supply and the remote device; a voltage monitor configured to determine a first voltage between the weld cable and the reference conductor while substantially zero current is being conducted through the reference conductor; and a receiver circuit configured to receive a second voltage between the weld cable and the reference conductor from the remote device.

Welding power supplies, wire feeders, and systems to measure a weld cable voltage drop

A welding-type power supply that receives alternating current (AC) input power and converts the AC input power to direct current (DC) power to provide power for welding tools. The welding-type power supply is configured to detect whether single phase AC power or three-phase AC power is connected to the input of welding-type power supply. Single phase input power may be detected by sampling ripple voltage of the DC power, either synchronously with the AC input power or synchronously with a signal generated by an output of the welding-type power supply.

Single phase input detection and power source protection

Systems and methods to reduce magnetic flux in a switched mode power supply are disclosed. An example welding-type power supply includes a switched mode power supply, including a transformer configured to transform an input voltage to a welding-type voltage; switches configured to control a voltage applied to the primary winding of the transformer; a current detector configured to measure a current through the primary winding; a flux accumulator configured to determine a net flux in the transformer based on a number of volt-seconds applied to the primary winding of the transformer; and a controller configured to: control duty cycles of the switches based on the net flux; and set a value of the net flux in response to the current through the primary winding satisfying a current threshold.

Systems and methods to reduce magnetic flux in a transformer in a switched mode power supply

Systems and methods to estimate magnetic flux in a switched mode power supply are disclosed. An example welding-type power supply includes a switched mode power supply, comprising: a transformer configured to transform an input voltage to a welding-type voltage; a capacitor in series with a primary winding of the transformer; and switches configured to control a voltage applied to a series combination of the primary winding of the transformer and the capacitor; a voltage estimator coupled to the transformer and configured to output a signal representative of an alternating-current (AC)-coupled voltage at the capacitor; and a flux accumulator to determine a net flux in the transformer based on the voltage applied to the series combination of the primary winding of the transformer and the capacitor.

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Oshkosh, WI, United States of America

Adam E Anders