US6236014B1
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US
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Method and apparatus for providing welding/plasma power
Assignee: Illinois Tool Works Inc
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Filing: 1999-12-20
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Granted: 2001-05-22
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Expires: 2019-12-20
Abstract
Abstract A method and apparatus for providing welding/plasma power is disclosed. The welding/plasma power source includes an input stage, an output stage, and an energy storage device such as a capacitor. The input stage is configured to receive an ac input signal and to rectify the ac input signal to provide a rectified intermediate signal. The input stage is further configured to provide a dc voltage signal across a dc bus. The output stage is disposed to receive the dc voltage signal and is configured to provide an available output power signal suitable for welding, plasma cutting and induction heating applications. The energy storage device is connected to provide sufficient stored energy to the dc bus to allow the welding/plasma power source to run off of a generator.
Inventors
- 👤 James F. Ulrich
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 23:27
CPC Classifications
H; H05; H05H; H05H1/00; H05H1/24; H05H1/26; H05H1/32; H05H1/34; H05H1/36; B; B23; B23K; B23K10/00; B23K10/006
Claims Analysis
Total Claims: 52
Claim 1
Independent Claim
120 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal having a period of T seconds and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal having a power of P watts; and a bus capacitor connected across the dc bus wherein the bus capacitor has a capacitance of at least (3PT)/(V 2 ) farads.
Claim 2
Dependent Claim
120 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal having a period of T seconds and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal having a power of P watts; and a bus capacitor connected across the dc bus wherein the bus capacitor has a capacitance of at least (3PT)/(V 2 ) farads.
Claim 3
Dependent Claim
16 words
The welding/plasma power source of claim 1 wherein the capacitance is at least (4PT)/(V 2 ).
Claim 4
Dependent Claim
16 words
The welding/plasma power source of claim 1 wherein the capacitance is at least (5PT)/(V 2 ).
Claim 5
Dependent Claim
22 words
The welding/plasma power source of claim 1 wherein the input stage includes an input rectifier configured to receive the ac input signal.
Claim 6
Dependent Claim
22 words
The welding/plasma power source of claim 4 wherein the input stage further includes a converter configured to provide the dc voltage signal.
Claim 7
Dependent Claim
14 words
The welding/plasma power source of claim 5 wherein the converter is a boost converter.
Claim 8
Dependent Claim
14 words
The welding/plasma power source of claim 5 wherein the converter is a buck converter.
Claim 9
Dependent Claim
21 words
The welding/plasma power source of claim 1 wherein the input stage includes a converter configured to provide the dc voltage signal.
Claim 10
Dependent Claim
21 words
The welding/plasma power source of claim 1 wherein the output stage includes an inverter disposed to receive the dc voltage signal.
Claim 11
Dependent Claim
16 words
The welding/plasma power source of claim 9 wherein the inverter is a pulse width modulating inverter.
Claim 12
Dependent Claim
24 words
The welding/plasma power source of claim 9 wherein the output stage further includes an output transformer configured to provide the available output power signal.
Claim 13
Dependent Claim
24 words
The welding/plasma power source of claim 9 wherein the output stage further includes an output rectifier configured to provide the available output power signal.
Claim 14
Dependent Claim
23 words
The welding/plasma power source of claim 1 wherein the output stage includes an output rectifier configured to provide the available output power signal.
Claim 15
Dependent Claim
124 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal having a period of T seconds and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal having a power of P watts; and an energy storage device connected to provide stored energy to the dc bus, wherein the energy storage device can store energy of at least (1.5)(PT) joules.
Claim 16
Dependent Claim
124 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal having a period of T seconds and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal having a power of P watts; and an energy storage device connected to provide stored energy to the dc bus, wherein the energy storage device can store energy of at least (1.5)(PT) joules.
Claim 17
Dependent Claim
20 words
The welding/plasma power source of claim 14 wherein the energy storage device can store energy of at least (2)(PT) joules.
Claim 18
Dependent Claim
20 words
The welding/plasma power source of claim 14 wherein the energy storage device can store energy of at least (2.5)(PT) joules.
Claim 19
Dependent Claim
106 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal; and a bus capacitor connected across the dc bus wherein the bus capacitor has a capacitance of at least 438 microfarads.
Claim 20
Dependent Claim
106 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal; and a bus capacitor connected across the dc bus wherein the bus capacitor has a capacitance of at least 438 microfarads.
Claim 21
Dependent Claim
15 words
The welding/plasma power source of claim 17 wherein the capacitance is at least 500 microfarads.
Claim 22
Dependent Claim
15 words
The welding/plasma power source of claim 17 wherein the capacitance is at least 583 microfarads.
Claim 23
Dependent Claim
15 words
The welding/plasma power source of claim 17 wherein the capacitance is at least 729 microfarads.
Claim 24
Dependent Claim
100 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal from a utility source and a generator source and further wherein the input stage provides a dc bus signal; an output stage disposed to receive the dc bus signal and configured to provide an available output power wherein the available output power has a first value when the ac input signal is from the utility source and a second value when the ac input signal is from the generator source and further wherein the second value is at least seventy-five percent of the first value.
Claim 25
Dependent Claim
100 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal from a utility source and a generator source and further wherein the input stage provides a dc bus signal; an output stage disposed to receive the dc bus signal and configured to provide an available output power wherein the available output power has a first value when the ac input signal is from the utility source and a second value when the ac input signal is from the generator source and further wherein the second value is at least seventy-five percent of the first value.
Claim 26
Dependent Claim
20 words
The welding/plasma power source of claim 21 wherein the second value is at least ninety percent of the first value.
Claim 27
Dependent Claim
20 words
The welding/plasma power source of claim 21 wherein the second value is at least ninety-five percent of the first value.
Claim 28
Dependent Claim
121 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal; and an energy storage device connected to provide stored energy to the dc bus, wherein the energy storage device can store sufficient energy to maintain the available output power signal through the duration of mechanical transients.
Claim 29
Dependent Claim
121 words
A welding/plasma power source comprising: an input stage configured to receive an ac input signal and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal; and an energy storage device connected to provide stored energy to the dc bus, wherein the energy storage device can store sufficient energy to maintain the available output power signal through the duration of mechanical transients.
Claim 30
Dependent Claim
150 words
A welding/plasma power source comprising: a generator source configured to provide an ac input signal wherein the ac input signal includes at least one mechanical transient; an input stage configured to receive the ac input signal from the generator source and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal; and an energy storage device connected to provide stored energy to the dc bus, wherein the energy storage device can store sufficient energy to maintain the available output power signal through the duration of the at least one mechanical transient.
Claim 31
Dependent Claim
150 words
A welding/plasma power source comprising: a generator source configured to provide an ac input signal wherein the ac input signal includes at least one mechanical transient; an input stage configured to receive the ac input signal from the generator source and to rectify the ac input signal to provide a rectified intermediate signal having a peak voltage and further wherein the input stage provides a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; an output stage disposed to receive the dc voltage signal and configured to provide an available output power signal; and an energy storage device connected to provide stored energy to the dc bus, wherein the energy storage device can store sufficient energy to maintain the available output power signal through the duration of the at least one mechanical transient.
Claim 32
Independent Claim
93 words
A method of providing welding/plasma power comprising: receiving an ac input signal having a period of T seconds; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal having a power of P watts; and providing a capacitance of at least (3PT)/(V 2 ) farads across the dc bus.
Claim 33
Independent Claim
93 words
A method of providing welding/plasma power comprising: receiving an ac input signal having a period of T seconds; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal having a power of P watts; and providing a capacitance of at least (3PT)/(V 2 ) farads across the dc bus.
Claim 34
Dependent Claim
14 words
The method of claim 26 wherein the capacitance is at least (4PT)/(V 2 ).
Claim 35
Dependent Claim
14 words
The method of claim 26 wherein the capacitance is at least (5PT)/(V 2 ).
Claim 36
Independent Claim
100 words
A method of providing welding/plasma power comprising: receiving an ac input signal having a period of T seconds; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal having a power of P watts; and providing stored energy to the dc bus from an energy storage device capable of storing at least (1.5)(PT) joules of energy.
Claim 37
Independent Claim
100 words
A method of providing welding/plasma power comprising: receiving an ac input signal having a period of T seconds; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal having a power of P watts; and providing stored energy to the dc bus from an energy storage device capable of storing at least (1.5)(PT) joules of energy.
Claim 38
Dependent Claim
18 words
The method of claim 29 wherein the energy storage device can store energy of at least (2)(PT) joules.
Claim 39
Dependent Claim
18 words
The method of claim 29 wherein the energy storage device can store energy of at least (2.5)(PT) joules.
Claim 40
Independent Claim
78 words
A method of providing welding/plasma power comprising: receiving an ac input signal; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal; and providing capacitance of at least 438 microfarads across the dc bus.
Claim 41
Independent Claim
78 words
A method of providing welding/plasma power comprising: receiving an ac input signal; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal; and providing capacitance of at least 438 microfarads across the dc bus.
Claim 42
Dependent Claim
13 words
The method of claim 32 wherein the capacitance is at least 500 microfarads.
Claim 43
Dependent Claim
13 words
The method of claim 32 wherein the capacitance is at least 583 microfarads.
Claim 44
Dependent Claim
13 words
The method of claim 32 wherein the capacitance is at least 729 microfarads.
Claim 45
Independent Claim
87 words
A method of providing welding/plasma power comprising: receiving an ac input signal from at least one of a utility source and a generator source; providing a dc bus signal; receiving the da bus signal; providing an available output power wherein the available output power has a first value when the ac input signal is from the utility source and a second value when the ac input signal is from the generator source and further wherein the second value is at least seventy-five percent of the first value.
Claim 46
Independent Claim
87 words
A method of providing welding/plasma power comprising: receiving an ac input signal from at least one of a utility source and a generator source; providing a dc bus signal; receiving the da bus signal; providing an available output power wherein the available output power has a first value when the ac input signal is from the utility source and a second value when the ac input signal is from the generator source and further wherein the second value is at least seventy-five percent of the first value.
Claim 47
Dependent Claim
18 words
The method of claim 36 wherein the second value is at least ninety percent of the first value.
Claim 48
Dependent Claim
18 words
The method of claim 36 wherein the second value is at least ninety-five percent of the first value.
Claim 49
Independent Claim
97 words
A method of providing welding/plasma power comprising: receiving an ac input signal; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal; and providing stored energy to the dc bus from an energy storage device capable of storing sufficient energy to maintain the available output power signal through the duration of mechanical transients.
Claim 50
Independent Claim
97 words
A method of providing welding/plasma power comprising: receiving an ac input signal; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal; and providing stored energy to the dc bus from an energy storage device capable of storing sufficient energy to maintain the available output power signal through the duration of mechanical transients.
Claim 51
Independent Claim
121 words
A method of providing welding/plasma power comprising: providing an ac input signal from a generator source wherein the ac input signal includes at least one mechanical transient; receiving the ac input signal; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal; and providing stored energy to the dc bus from an energy storage device capable of storing sufficient energy to maintain the available output power signal through the duration of the at least one mechanical transient.
Claim 52
Independent Claim
121 words
A method of providing welding/plasma power comprising: providing an ac input signal from a generator source wherein the ac input signal includes at least one mechanical transient; receiving the ac input signal; rectifying the ac input signal to provide a rectified intermediate signal having a peak voltage; providing a dc voltage signal having a voltage of V volts across a dc bus, wherein V is greater than the peak voltage of the rectified intermediate signal; receiving the dc voltage signal; providing an available output power signal; and providing stored energy to the dc bus from an energy storage device capable of storing sufficient energy to maintain the available output power signal through the duration of the at least one mechanical transient.
References Cited (Backward Citations)
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2004-05-21 | 2004-11-20 | 2005-05-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-05-21 | 2008-11-20 | 2009-05-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-05-21 | 2012-11-20 | 2013-05-22 | $7700.00 | Window Closed / Lapsed |