US20210197305A1 - Welder Apparatus and Methods - Google Patents
Welder Apparatus and Methods Download PDFInfo
- Publication number
- US20210197305A1 US20210197305A1 US17/200,571 US202117200571A US2021197305A1 US 20210197305 A1 US20210197305 A1 US 20210197305A1 US 202117200571 A US202117200571 A US 202117200571A US 2021197305 A1 US2021197305 A1 US 2021197305A1
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- US
- United States
- Prior art keywords
- power
- inductor
- welding
- processing circuitry
- source
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 20
- 238000003466 welding Methods 0.000 claims abstract description 22
- 230000008569 process Effects 0.000 claims abstract description 14
- 239000007789 gas Substances 0.000 claims description 5
- 238000004804 winding Methods 0.000 description 3
- 239000010979 ruby Substances 0.000 description 2
- 229910001750 ruby Inorganic materials 0.000 description 2
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000003190 augmentative effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
- B23K9/1043—Power supply characterised by the electric circuit
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1081—Arc welding by means of accumulated energy
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2823—Wires
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Arc Welding Control (AREA)
- Charge And Discharge Circuits For Batteries Or The Like (AREA)
Abstract
Processes of providing power to a welding wand are provided that include pulsing power from a power source to an inductor, and then providing constant power from the inductor to the welding wand.
Description
- This application is a divisional of U.S. patent application Ser. No. 15/340,904 which was filed Nov. 1, 2016, entitled “Welder Apparatus and Methods”, which claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 62/249,555 which was filed on Nov. 2, 2015, entitled “Welder Apparatus and Methods”, the entirety of each of which is incorporated by reference herein.
- The technical field is welding apparatus and methods, particularly, battery powered and/or portable welding apparatus and methods.
- For shop work, such as automobile repair, for example, it is more and more important to be able to weld materials in an inert atmosphere utilizing welders that have constant feed wiring assemblies. It is desirable that these welders are small and/or portable and can be moved to different locations of the shop and/or transported using a vehicle to remote locations outside the shop, for example. The present disclosure provides a welder assembly that can utilize automotive type batteries and be portable to different locations while providing constant feed wiring for welding in inert locations.
- Embodiments of the disclosure are described below with reference to the following accompanying drawings.
-
FIG. 1 is a welding apparatus according to an embodiment of the disclosure. -
FIG. 2 is another view of the welding apparatus ofFIG. 1 according to an embodiment of the disclosure. -
FIG. 3 is a controller board for use within the welding apparatus ofFIGS. 1 and 2 according to an embodiment of the disclosure. -
FIG. 4 is an example inductor configuration according to an embodiment of the disclosure. -
FIGS. 5A, 5B and 5C are inductor configurations for use with the welding apparatus according to an embodiment of the disclosure. - This disclosure is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
- The welding apparatus and methods will be described with reference to
FIGS. 1-5C . Referring first toFIG. 1 ,welding apparatus 10 includes abattery package 12 that can be for example, two 12 volt wet cell automotive type batteries that are connected in series to provide 24 volt power when the power switch is closed. The power switch can be electrically located between the positive terminal of the lower 12 volt battery and the negative terminal of the upper 12 volt battery (not shown). The batteries can be rechargeable with a dual 12 volt charger system that mounts to the top of the chassis, for example. The two 12 volt batteries can be located on the bottom shelf of the welder chassis as shown inapparatus 10.Apparatus 10 can also include aprocessing circuitry board 14 as well as aninductor 16. These components can be contained withinhousing 18 as shown. - Referring next to
FIG. 2 ,apparatus 10 is shown in another view to depicthousing 18 that encompassesinductor 16 as well as constant feed wiring spool 20, for example.Component 19 houses a portable battery charger than may be used with or withoutapparatus 10. This battery charger is of standard components but configured to accompany the small footprint ofapparatus 10 as desired. - Referring next to
FIG. 3 , anexample circuit board 14 is shown.Circuit board 14 can include processing circuitry. The processor can include personal computing system that includes a computer processing unit that can include one or more microprocessors, one or more support circuits, circuits that include power supplies, clocks, input/output interfaces, circuitry, and the like. Generally, all computer processing units described herein can be of the same general type. The computing system can include a memory that can include random access memory, read only memory, removable disc memory, flash memory, and various combinations of these types of memory. The memory can be referred to as a main memory and be part of a cache memory or buffer memory. The memory can store various software packages and components such as an operating system. The computing system may also include a web server that can be of any type of computing device adapted to distribute data and process data requests. The web server can be configured to execute system application software such as the reminder schedule software, databases, electronic mail, and the like. The memory of the web server can include system application interfaces for interacting with users and one or more third party applications. Computer systems of the present disclosure can be standalone or work in combination with other servers and other computer systems that can be utilized, for example, with larger corporate systems such as financial institutions, insurance providers, and/or software support providers. The system is not limited to a specific operating system but may be adapted to run on multiple operating systems such as, for example, Linux and/or Microsoft Windows. The computing system can be coupled to a server and this server can be located on the same site as computer system or at a remote location, for example. - In accordance with example implementations, these processes may be utilized in connection with the processing circuitry described. The processes may use software and/or hardware of the following combinations or types. For example, with respect to server-side languages, the circuitry may use Java, Python, PHP, .NET, Ruby, Javascript, or Dart, for example. Some other types of servers that the systems may use include Apache/PHP, .NET, Ruby, NodeJS, Java, and/or Python. Databases that may be utilized are Oracle, MySQL, SQL, NoSQL, or SQLLite (for Mobile). Client-side languages that may be used, this would be the user side languages, for example, are ASM, C, C++, C#, Java, Objective-C, Swift, Actionscript/Adobe AIR, or Javascript/HTML5. Communications between the server and client may be utilized using TCP/UDP Socket based connections, for example, as Third Party data network services that may be used include GSM, LTE, HSPA, UMTS, CDMA, WiMax, WiFi, Cable, and DSL. The hardware platforms that may be utilized within processing circuitry include embedded systems such as (Raspberry PI/Arduino), (Android, iOS, Windows Mobile)—phones and/or tablets, or any embedded system using these operating systems, i.e., cars, watches, glasses, headphones, augmented reality wear etc., or desktops/laptops/hybrids (Mac, Windows, Linux). The architectures that may be utilized for software and hardware interfaces include x86 (including x86-64), or ARM.
- This processing circuitry can be configured to control the welder and be part of and also include a weld control board, FET switches, current sensor, and control potentiometers. This control can monitor the weld current and system voltage to ensure that the system is working within the established limits set in the firmware of the master control unit, which is also part of the processing circuitry. As an example, by switching the FET switches on and off, a pulsating DC current is fed to the weld inductor that generates the welding power. The processing circuitry board is also coupled to control power from the batteries to the inductor that also has a feedback loop as part of the firmware that allows for consistent power. As an example, the processing circuitry will pulse power to the inductor, but with the feedback loop, the inductor would generate a constant power. This power is generated as the inductor extends the 24 volts provided to an enhanced power.
- Referring next to
FIG. 4 , an example inductor can include a common mode inductor, bracketed or extending to a circular inductor and a capacitor on the extended end of the common mode inductor. This is just one inductor example configuration. According to another example inductor configuration and with reference toFIGS. 5A-5C , and inductor can include at least three components: afill coil 60 that is comprised of a laminated portion such as 120 pieces of lamination that are in a 2.25 inch wedge stacked tightly to prevent movement within the stack. This fill coil can be within a 6 layer wind that can include wire windings about aframe interior 62 that forms a tube; the windings can be configured as shown in 64. They can be 22 turns of 0.124×0.248 HAPT magnetic wire over start wires as shown to form finish wire back over coil. As an example, these components can be constructed to extend toends component 60 being approximately 0.2 inches above the windings ofcomponent 64. - In operation of
welding apparatus 10, gas piping can bring inert gas into the gas solenoid valve with opens and closes depending on the welding switch trigger position desired. The piping can carry gas to the wire feed mechanism, which has the piping and welding wand integrated into it as shown. There are example operating scenarios, such as turning the switch as shown on the front panel to the on position. Adjusting the wire feed and power potentiometers can change voltages to the controller. These voltages can set up duty cycles that will be used to drive the wire feed motor and the welding power. The processing circuitry can be configured to check the battery voltages to ensure that they are adequate for welding operations and can go into standby mode to wait for the trigger switch to close. When the trigger switch is closed, the controller opens the gas flow valve, and DC pulses start the wire feed motor feeding wire down the wand. Welding continues until the trigger is released, for example. According to example implementations, the main power switch can be connected between the positive side of the lower battery and the negative side of the upper battery. Closing the switch turns on 24 volt power to the system, and there is a 12 volt voltmeter that can be configured to monitor one or more of the batteries to report on system power levels. Batteries can be recharged with a 12 volt charger accessory mounted on top of the system. Current can be monitored by a current transformer on the negative bus bar, for example. Voltage can be monitored from the power supply. - In compliance with the statute, embodiments of the invention have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the entire invention is not limited to the specific features and/or embodiments shown and/or described, since the disclosed embodiments comprise forms of putting the invention into effect.
Claims (10)
1. A process of providing power to a welding wand that includes pulsing power from a power source to an inductor, and then providing constant power from the inductor to the welding wand.
2. The process of claim 1 wherein the power is pulsed from a DC power source.
3. The process of claim 2 wherein the DC power source is a battery source.
4. The process of claim 3 wherein the battery source is a 12 V battery source.
5. The process of claim 3 wherein the battery source is a pair of 12 V batteries.
6. The process of claim 5 wherein the pair of 12V batteries are aligned in series
7. The process of claim 1 further comprising using processing circuitry to facilitate the transfer of power from the power source to the inductor and then to the wand.
8. The process of claim 1 wherein the processing circuitry provides a feedback loop as part of firmware and monitors the providing of power using the feedback loop.
9. The process of claim 1 further comprising feeding wiring to the welding wand.
10. The process of claim 1 further comprising providing gases to the welding wand.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/200,571 US20210197305A1 (en) | 2015-11-02 | 2021-03-12 | Welder Apparatus and Methods |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201562249555P | 2015-11-02 | 2015-11-02 | |
US15/340,904 US10946466B1 (en) | 2015-11-02 | 2016-11-01 | Welder apparatus and methods |
US17/200,571 US20210197305A1 (en) | 2015-11-02 | 2021-03-12 | Welder Apparatus and Methods |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/340,904 Division US10946466B1 (en) | 2015-11-02 | 2016-11-01 | Welder apparatus and methods |
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US20210197305A1 true US20210197305A1 (en) | 2021-07-01 |
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Family Applications (2)
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US15/340,904 Active 2037-10-22 US10946466B1 (en) | 2015-11-02 | 2016-11-01 | Welder apparatus and methods |
US17/200,571 Pending US20210197305A1 (en) | 2015-11-02 | 2021-03-12 | Welder Apparatus and Methods |
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US15/340,904 Active 2037-10-22 US10946466B1 (en) | 2015-11-02 | 2016-11-01 | Welder apparatus and methods |
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US (2) | US10946466B1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050151518A1 (en) * | 2004-01-08 | 2005-07-14 | Schneiker Henry D. | Regulated open-loop constant-power power supply |
WO2010001336A1 (en) * | 2008-07-01 | 2010-01-07 | Nxp B.V. | Inductors and methods of manufacture thereof |
US20120006792A1 (en) * | 2010-07-09 | 2012-01-12 | Illinois Tool Works Inc. | Battery powered welding system |
Family Cites Families (16)
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US1509006A (en) | 1923-02-28 | 1924-09-16 | Earl B Thomas | Electrode holder |
US3210702A (en) | 1963-05-22 | 1965-10-05 | Kirkhof Mfg Corp | Potted welding transformer with a tap switch |
DE3200086C2 (en) | 1982-01-05 | 1994-09-01 | Peter Dr.-Ing. 5100 Aachen Puschner | Electronic welding energy source for arc welding with predefinable static and dynamic behavior |
US4475028A (en) | 1983-02-10 | 1984-10-02 | Newport News Shipbuilding & Dry Dock Co. | Multi-mode constant potential pulsed welding apparatus |
DE3534061A1 (en) | 1985-07-20 | 1987-01-22 | Peter W Bodewig | MIG / MAG WELDING MACHINE FOR PULSED ARC WELDING |
US5250786A (en) | 1990-09-27 | 1993-10-05 | Sawafuji Electric Co., Ltd. | D-C arc welding apparatus |
US6225596B1 (en) | 1996-03-20 | 2001-05-01 | Century Mfg. Co. | Portable welding unit |
US6204476B1 (en) | 1999-05-12 | 2001-03-20 | Illinois Tool Works | Welding power supply for pulsed spray welding |
US6479795B1 (en) | 2000-10-11 | 2002-11-12 | Illinois Tool Works Inc. | Portable welding wire feeder and housing |
DE10119283A1 (en) * | 2001-04-20 | 2002-10-24 | Philips Corp Intellectual Pty | System for wireless transmission of electric power, item of clothing, a system of clothing items and method for transmission of signals and/or electric power |
US6747246B2 (en) | 2002-03-04 | 2004-06-08 | Crandell, Iii John O. | Integrated mobile tool and welder power supply system |
US6794976B2 (en) * | 2002-12-24 | 2004-09-21 | Illinois Tool Works Inc. | HF transformer assembly having a higher leakage inductance boost winding |
AU2004253455B2 (en) | 2003-06-03 | 2011-03-03 | Eli Lilly And Company | Modulation of survivin expression |
US6818860B1 (en) | 2003-06-26 | 2004-11-16 | Lincoln Global, Inc. | Portable welder with integral battery charger |
US7183517B2 (en) | 2003-11-26 | 2007-02-27 | Illinois Tool Works, Inc. | Portable welding-type apparatus with interchangeable energy storage device |
US9399263B2 (en) | 2007-08-31 | 2016-07-26 | Hobart Brothers Company | Portable battery powered welder |
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2016
- 2016-11-01 US US15/340,904 patent/US10946466B1/en active Active
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2021
- 2021-03-12 US US17/200,571 patent/US20210197305A1/en active Pending
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050151518A1 (en) * | 2004-01-08 | 2005-07-14 | Schneiker Henry D. | Regulated open-loop constant-power power supply |
WO2010001336A1 (en) * | 2008-07-01 | 2010-01-07 | Nxp B.V. | Inductors and methods of manufacture thereof |
US20120006792A1 (en) * | 2010-07-09 | 2012-01-12 | Illinois Tool Works Inc. | Battery powered welding system |
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US10946466B1 (en) | 2021-03-16 |
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