U.S. patent application number 17/136715 was filed with the patent office on 2021-04-22 for engine driven generator for providing welding power.
The applicant listed for this patent is Illinois Tool Works Inc.. Invention is credited to Todd G. Batzier, Michael D. Madsen, Dennis R. Sigl.
Application Number | 20210114127 17/136715 |
Document ID | / |
Family ID | 1000005312984 |
Filed Date | 2021-04-22 |
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United States Patent
Application |
20210114127 |
Kind Code |
A1 |
Sigl; Dennis R. ; et
al. |
April 22, 2021 |
ENGINE DRIVEN GENERATOR FOR PROVIDING WELDING POWER
Abstract
A method and apparatus for providing engine driven welding-type
power supply includes an engine, a generator, an input power
circuit, a welding-type power circuit, an auxiliary power circuit
and a controller. The generator includes permanent magnets that
create and provides a generator output from at least one polyphase
winding. The input power circuit is connected to the generator
output and the welding-type power circuit is connected to the input
circuit, and provides a welding-type output. The auxiliary power
circuit is connected to the input circuit and provides an auxiliary
power output. The controller is connected to the auxiliary power
and the welding type power circuits, and can command that there be
no load for the generator. The generator is connected to the engine
and connected to function as a flywheel to the engine and the
engine does not include a flywheel other than the generator.
Inventors: |
Sigl; Dennis R.;
(Greenville, WI) ; Batzier; Todd G.; (Hortonville,
WI) ; Madsen; Michael D.; (Freemont, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Illinois Tool Works Inc. |
Glenview |
IL |
US |
|
|
Family ID: |
1000005312984 |
Appl. No.: |
17/136715 |
Filed: |
December 29, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15810921 |
Nov 13, 2017 |
10875118 |
|
|
17136715 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 9/1043 20130101;
B23K 9/1006 20130101 |
International
Class: |
B23K 9/10 20060101
B23K009/10 |
Claims
1-20. (canceled)
21. An engine driven welding-type power supply, comprising: an
engine; a generator, connected to the engine, and configured to
provide a generator output, wherein the generator includes exactly
one polyphase winding, wherein the generator output has more than
one phase and the generator output is derived from the polyphase
winding; an input power circuit connected to the generator output
and configured to preregulate power from the generator output to a
high voltage bus; a welding-type power circuit, connected to the
input circuit, and configured to provide a welding-type output; an
auxiliary power circuit connected to the input circuit, and
configured to provide an auxiliary power output; and a controller
connected to the auxiliary power circuit and the welding-type power
circuit.
22. The welding-type power supply of claim 21, wherein the
controller includes a no load module having an output connected to
the welding-type power circuit and the auxiliary power circuit.
23. The welding-type power supply of claim 21, wherein the engine
includes an air intake and an air flow path that receives air from
the air intake, and wherein the generator is located in the air
flow path.
24. The welding-type power supply of claim 21, wherein the
generator is connected to function as a flywheel to the engine, and
further wherein the engine does not include a flywheel other than
the generator.
25. The welding-type power supply of claim 21, wherein the
generator includes a rotor and the engine includes a shaft that
rotates the rotor, and wherein the rotor is near a first end of the
shaft, and wherein the first end of the shaft is cantilevered.
26. The welding-type power supply of claim 25, wherein shaft is
supported by at least one bearing within the engine and is not
supported by a bearing within the generator.
27. The welding-type power supply of claim 21, wherein the at least
one polyphase winding is a three phase winding.
28. The welding-type power supply of claim 21, wherein the at least
one polyphase winding is arranged in a Y connection and the
auxiliary output is a split phase auxiliary output.
Description
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to the art of
welding type power supplies that include a welding type power
circuit that receives power from an engine driven generator.
BACKGROUND OF THE INVENTION
[0002] There are many known types of welding-type power supplies.
Welding-type power, as used herein, refers to power suitable for
electric arc welding, plasma cutting or induction heating.
Welding-type systems are often used in a variety of applications
and often are used at sites where utility power is not available or
insufficient. In such applications welding type systems include, or
receive power from, an engine driven generator. Welding-type
system, as used herein, is a system that can provide welding type
power, and can include control and power circuitry, wire feeders,
and ancillary equipment, and/or an engine and generator.
[0003] Engine driven generators that are part of welding systems
are designed with numerous considerations. First, they often
attempt to mimic utility power because the welding power supply
portion of the system is often designed to be used with either
utility or engine power. Second, they often use a field coil and
select the number of poles and rotational frequency to produce 60
(or 50) Hz current. Third, the engine must be cooled and the
generator must be cooled. Fourth, the engine has a flywheel. Fifth,
the engine shaft must turn the generator rotor (and the shaft must
be supported to do so). Taking all of these factors into
consideration can lead to engines that operate less efficiently
than desired, and/or are more costly than desired
[0004] Prior art welding systems with an engine need a way to cool
the engine and generator power supply. Typically a fan for cooling
just the generator is provided. This fan adds cost and weight to
the system, and reduces overall efficiency of the system.
[0005] Prior art welding systems with a generator typically include
a shaft driven by the engine that extends to the generator. Such
shafts are typically supported at multiple locations, such as at
each end. Each support adds weight and cost to the system.
[0006] Prior art welding systems with an engine and generator
typically provide a flywheel as part of the engine. The flywheel is
necessary, but having a flywheel that is used solely as an engine
flywheel adds cost and weight to the system, and reduces overall
efficiency of the system.
[0007] Prior art welding systems typically use a field coil and
select the number of poles and rotational frequency to produce 60
(or 50) Hz current. This forces the number of poles to be chosen
based on the output frequency desired, rather than allowing the
generator to be designed in as efficient and cost effective manner
as possible.
[0008] Prior art welding-type systems often provide auxiliary power
outputs to power tools, etc. Auxiliary output power, as used herein
includes, power provided to mimic utility power, such as 50/60 Hz,
120/240/200V, e.g., that can be used to power devices such as
tools, lights, etc. U.S. Pat No. 6,987,242 describes system where
auxiliary power is derived using an inverter that creates a 575V
signal that is stepped down by an isolation transformer to an aux
power signal. Prior art aux power can be single phase or split
phase (two single phase outputs).
[0009] Accordingly, a welding-type system that has a poly phase
generator without multiple windings, and/or is able to cool the
generator without a dedicated cooling fan, and/or does not need a
dedicated flywheel for the engine, and/or uses a single support for
the generator shaft, and/or does not need to have the number of
poles tied to the frequency of the output is desirable.
SUMMARY OF THE PRESENT INVENTION
[0010] According to a first aspect of the disclosure an engine
driven welding-type power supply includes an engine, a generator,
an input power circuit, a welding-type power circuit, an auxiliary
power circuit and a controller. The generator is connected to the
engine, and provides a generator output from at least one polyphase
winding, thus the generator output has more than one phase. The
input power circuit is connected to the generator output and the
welding-type power circuit is connected to the input circuit, and
provides a welding-type output. The auxiliary power circuit is also
connected to the input circuit, and provides an auxiliary power
output. The controller is connected to the auxiliary power circuit
and the welding type power circuit.
[0011] According to a second aspect of the disclosure an engine
driven welding-type power supply includes an engine, a generator,
an input power circuit, a welding-type power circuit, an auxiliary
power circuit and a controller. The engine drives the generator,
and the generator includes a plurality of permanent magnets that
create an excitation field, and the generator provides a generator
output. The input power circuit is connected to the generator
output, and the welding-type power circuit is connected to the
input circuit to provide a welding-type output. The auxiliary power
circuit is also connected to the input circuit, and provides an
auxiliary power output. The controller is connected to the
auxiliary power circuit and the welding type power circuit.
[0012] According to a third aspect of the disclosure an engine
driven welding-type power supply includes an engine, a generator,
an input power circuit, a welding-type power circuit, an auxiliary
power circuit and a controller. The generator is connected to the
engine and connected to function as a flywheel to the engine. The
engine does not include a flywheel other than the generator. The
welding-type power circuit is connected to the input circuit and
provides a welding-type output. The auxiliary power circuit is
connected to the input circuit to provide an auxiliary power
output. The controller is connected to the auxiliary power circuit
and the welding type power circuit.
[0013] The controller can command that there be no load for the
generator, such as by having a no load module, in one
embodiment.
[0014] The generator includes a plurality of permanent magnets that
creates an excitation field in one alternative.
[0015] The engine includes an air intake and an air flow path that
receives air from the air intake, and the generator is located in
the air flow path in another alternative.
[0016] The generator is connected to function as a flywheel to the
engine, and the engine does not include a flywheel other than the
generator in one embodiment.
[0017] The generator includes a rotor and the engine includes a
shaft that rotates the rotor, and the rotor is cantilevered at an
end of the shaft in various embodiments.
[0018] The engine shaft is supported only by bearings in the engine
and not by a bearing in the generator.
[0019] The polyphase winding is a three phase winding in another
alternative.
[0020] The polyphase winding is arranged in a Y connection and the
auxiliary output is a split phase auxiliary output in one
embodiment.
[0021] Other principal features and advantages of will become
apparent to those skilled in the art upon review of the following
drawings, the detailed description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a block diagram of an engine driven welding-type
power supply in accordance with this disclosure;
[0023] FIG. 2 is a diagram of engine and generator in accordance
with this disclosure;
[0024] FIG. 3 is a diagram of engine and generator in accordance
with this disclosure;
[0025] FIG. 4 is a diagram of part of a generator in accordance
with this disclosure;
[0026] FIG. 5 is a diagram of part of a generator in accordance
with this disclosure;
[0027] FIG. 6 is a diagram of part of a generator in accordance
with this disclosure; and
[0028] FIG. 7 is a diagram of windings of a generator in accordance
with this disclosure.
[0029] Before explaining at least one embodiment in detail it is to
be understood that the invention is not limited in its application
to the details of construction and the arrangement of the
components set forth in the following description or illustrated in
the drawings. The invention is capable of other embodiments or of
being practiced or carried out in various ways. Also, it is to be
understood that the phraseology and terminology employed herein is
for the purpose of description and should not be regarded as
limiting. Like reference numerals are used to indicate like
components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] While the present disclosure will be illustrated with
reference to a particular implementation with particular
components, it should be understood at the outset that the engine
driven generator for producing welding type power can also be
implemented with other components and designs.
[0031] The preferred embodiment is directed to an engine driven
welding-type power supply that includes an engine, a generator, an
input power circuit, a welding-type power circuit, an auxiliary
power circuit and a controller that cooperate to provide welding
type power. Welding type power, as used herein, refers to welding,
plasma cutting, induction heating, CAC-A and/or hot wire
welding/preheating (including laser welding and laser cladding)
power. Welding-type power supply, as used herein, includes any
device capable of supplying welding, plasma cutting, induction
heating, CAC-A and/or hot wire welding/preheating (including laser
welding and laser cladding) power, including resonant power
supplies, quasi-resonant power supplies, etc., as well as control
circuitry and other ancillary circuitry associated therewith.
[0032] The generator is connected to the engine, and a shaft in the
engine turns a rotor in the generator. The rotor is preferably
cantilevered at an end of the shaft, although it is not in various
embodiments. The engine shaft is preferably supported only by
bearings within the engine and not by bearings in the generator in
one alternative. The engine preferably includes an air intake and
an air flow path that receives air from the air intake, and the
generator is located in the air flow path in another
alternative.
[0033] The generator preferably includes a plurality of permanent
magnets that create an excitation field. The generator provides a
generator output from at least one polyphase winding in one
embodiment, thus the generator output has more than one phase. The
polyphase winding is preferably a three phase winding arranged in a
Y connection. The generator preferably functions as a flywheel to
the engine, and the engine does not include a flywheel other than
the generator. Flywheel to the engine, as used herein, refers to a
flywheel that stores mechanical energy produced by the engine. The
flywheel also may serve as an air mover, the rotor for the engine's
charging circuit, or the rotor of the main power generator, or any
combination thereof.
[0034] The input power circuit is connected to the generator output
and may be an input circuit such as that found in the prior art.
Preferably the input circuit is a preregulator, but can be a simple
rectifier and/or filter in various embodiments. Input circuit, as
used herein, includes circuits configured to receive an ac input
signal and to provide a dc output signal and may include as part
thereof a rectifier, a transformer, a saturable reactor, a
converter, an inverter, a filter, and/or a magnetic amplifier
[0035] The welding-type power circuit (or welding type power output
circuit) is connected to the input circuit, and provides
welding-type output power. The welding type power circuit can be
any topology, but is preferably a switched mode power circuit.
Welding-type output power circuit, as used herein includes, the
circuitry used to deliver welding-type power to the output studs.
Welding type output power, as used herein, refers to output power
suitable for welding, plasma cutting, induction heating, CAC-A
and/or hot wire welding/preheating (including laser welding and
laser cladding).
[0036] The auxiliary power circuit is also connected to the input
circuit, and provides an auxiliary power output. Preferably, the
auxiliary output is a split phase auxiliary output. The auxiliary
power can be any topology, but preferably includes an inverter to
produce synthetic aux power. Auxiliary power circuit, as used
herein includes, circuitry used to provide auxiliary output power.
Auxiliary output power, as used herein includes, power provided to
mimic utility power, such as 50/60 Hz, 120/240/200V, e.g., that can
be used to power devices such as tools, lights, etc.
[0037] The controller is connected to the auxiliary power circuit
and the welding type power circuit, and provides control signals to
the switches in the auxiliary power circuit and the welding type
power circuit. The controller can command that there be no load for
the generator at start up or when the engine needs to increase
speed. This allows the engine to more quickly increase its power
output because there is not a drag on the engine and/or the engine
is not snubbed. This embodiment is particularly suited for use with
a permanent magnet because there's no way to "shut off the field"
in a permanent magnet. Alternatives providing for reducing the load
to a smaller amount, rather than commanding it to zero. Energy for
the aux load or welding load can be derived from a storage device
such as batteries or electrolytic capacitors, or the load can
simply be delayed until the engine is up to speed. The load for the
generator is preferably commanded to zero by a no load module,
which is part of the controller. No load module, as used herein, is
a module that commands the load for the generator to be zero when
it would be more than zero absent the no load module, and does so
in response to actual or desired changes in engine speed or engine
starting. Alternatively, the load for the generator is reduced
using a reduced load module, which is part of the controller.
Reduced load module, as used herein, is a module that commands the
load for the generator to be reduced to less than it would be
absent the reduced load module, and does so in response to actual
or desired changes in engine speed or engine starting. No load for
the generator, as used herein, refers to no welding type power and
no auxiliary power being drawn from the generator. Controller, as
used herein, includes digital and analog circuitry, discrete or
integrated circuitry, microprocessors, DSPs, FPGAs, etc., and
software, hardware and firmware, located on one or more boards,
used to control all or part of a welding-type system or a device
such as a power supply, power source, engine or generator.
[0038] Turning now to FIG. 1 a block diagram of an engine driven
welding-type power supply 100 includes an engine 102, a generator
104, an input power circuit 106, a welding-type power circuit 108,
an auxiliary power circuit 110 and a controller 112. Engine 102
provides motive power to generator 104. Generator 104 generates
electrical power and provides that power to input circuit 106.
Input circuit 106 preferably preregulates the power for generator
104 to provide a relatively high voltage bus (880V e.g.) to
welding-type power circuit 108 and auxiliary power circuit 110.
Circuits 108 and 110 are preferably switch mode power supplies and
the switches thereon are controlled by controller 112 to provide a
welding power output 114 from welding-type power circuit 108 and a
split phase aux power output 115 output from auxiliary power
circuit 110.
[0039] Controller 112 also receives control power from input
circuit 106, which is used to power the control circuitry of
controller 112. Feedback may be provided from the welding output,
the aux output, and/or early stages.
[0040] Engine 102 and generator 104 may be a conventional engine
and generator found in prior art welding type systems, except as
described herein. Engine 102 includes an air flow path 200 (FIG. 2)
that receives air from the air intake. Generator 104 is preferably
located in air flow path 200. Airflow is provided to the engine by
a single fan, and that airflow can cool the engine and the
generator. A separate fan to cool the generator is not needed when
the generator is in the air flow path Generator 104 is mounted on a
shaft 202 and connected to serve as a flywheel to engine 102, and
engine 102 does not include a flywheel. Block 201 represents the
reminder of engine 102, which can be consistent with the prior art,
except for the absence of a fly wheel other than generator 104 and
as otherwise discussed.
[0041] Referring now to FIG. 3 generator 104 includes a rotor 302
and a stator 303. Rotor 302 is mounted on shaft 202. Preferably
rotor 302 is mounted near the end of shaft 202 and is cantilevered.
Also, shaft 202 is supported by bearings 304 within engine 102, and
not by bearings within generator 104. Generator 104 is shown in
more detail in FIGS. 4 and 5, and preferably includes permanent
magnets 401 that create an excitation field. from a polyphase
winding. FIG. 5 shows permanent magnets 401 with rotor 302
transparent.
[0042] Referring now to FIG. 6, a cut away view of generator 104
shows a single polyphase winding 601. Poly phase winding 601 is a
three phase winding in the preferred embodiment. Referring now to
FIG. 7, polyphase winding 601 is arranged in a grounded WYE
connection.
[0043] Thus, it should be apparent that there has been provided a
method and apparatus for providing welding type power with an
engine and generator that fully satisfies the objectives and
advantages set forth above. Although the disclosure has been
described specific embodiments thereof, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, the invention is intended to
embrace all such alternatives, modifications and variations that
fall within the spirit and broad scope of the appended claims.
* * * * *