EP-4737043-A2 - BATTERY-POWERED WELDING MACHINE

EP4737043A2EP 4737043 A2EP4737043 A2EP 4737043A2EP-4737043-A2

Abstract

A battery-powered welding machine includes a battery, charging circuitry operatively connected to the battery, and output circuitry operatively connected to the battery to receive electrical energy therefrom to create a welding arc. The output circuitry includes a bleed circuit to selectively discharge residual energy in the output circuitry. An isolation switch is connected between battery and the output circuitry to selectively connect and disconnect the battery from the output circuitry. A control system is operatively connected to the isolation switch to control operations of the isolation switch, and operatively connected to the bleed circuit to control discharging of the residual energy in the output circuitry. The control system is configured to detect a high voltage condition within the output circuitry and, when the high voltage condition is detected, automatically operate the isolation switch to disconnect the battery from the output circuitry, and automatically activate the bleed circuit to discharge the residual energy.

Inventors

MAKOSKY, JUSTIN M.
Slesinger, Andrew J.
Winarski, Nicholas F.
CRESCENZE, SAMUEL P.
CHAUDHAR, Pankajkumar H.

Assignees

Lincoln Global, Inc.

Dates

Publication Date: 20260506
Application Date: 20251014

Claims (13)

A battery-powered welding machine, comprising: a battery (114); charging circuitry (116) operatively connected to the battery (114) to charge the battery (114); output circuitry operatively connected to the battery (114) to receive electrical energy from the battery (114) to create a welding arc (106), wherein the output circuitry includes a bleed circuit to selectively discharge residual energy in the output circuitry; an isolation switch (118) connected between battery (114) and the output circuitry to selectively connect and disconnect the battery (114) from the output circuitry; and a control system operatively connected to the isolation switch (118) to control operations of the isolation switch (118), and operatively connected to the bleed circuit to control discharging of the residual energy in the output circuitry, wherein the control system is configured to detect a high voltage condition within the output circuitry and, when the high voltage condition is detected, automatically operate the isolation switch (118) to disconnect the battery (114) from the output circuitry, and automatically activate the bleed circuit to discharge the residual energy in the output circuitry.
The battery-powered welding machine of claim 1, wherein a battery voltage level supplied to the output circuitry is greater than 60 V, wherein the output circuitry preferably includes a chopper (108).
The battery-powered welding machine of claim 2, further comprising: a current sensor operatively connected to the control system, wherein the current sensor provides a welding current level signal to the control system, and the control system is configured to detect a high current condition within the output circuitry and, when the high current condition is detected, automatically operate the isolation switch (118) to disconnect the battery (114) from the output circuitry.
The battery-powered welding machine of any of claims 2 or 3, further comprising: an additional isolation switch (118) that is connected between battery (114) and the charging circuitry (116) to selectively connect and disconnect the battery (114) from the charging circuitry (116); and a current sensor operatively connected to the control system, wherein the current sensor provides a welding current level signal to the control system, and the control system is configured automatically operate the additional isolation switch (118) to disconnect the battery (114) from the charging circuitry (116) during a welding operation.
The battery-powered welding machine of claim 4, wherein the welding operation is shielded metal arc welding or gas tungsten arc welding.
The battery-powered welding machine of any of claims 4 or 5, wherein the control system is configured to automatically operate the additional isolation switch (118) to disconnect the battery (114) from the charging circuitry (116) based on the welding current level signal, wherein the residual energy preferably is stored in a capacitor, and the bleed circuit includes a resistor for discharging the capacitor.
A battery-powered welding machine, comprising: a battery (114); charging circuitry (116) operatively connected to the battery (114) to charge the battery (114); output circuitry operatively connected to the battery (114) to receive electrical energy from the battery (114) to create a welding arc (106), wherein the output circuitry includes a bleed circuit to selectively discharge residual energy in the output circuitry; a current sensor that generates a welding current level signal; an isolation switch (118) connected between battery (114) and the charging circuitry (116) to selectively connect and disconnect the battery (114) from the charging circuitry (116); and a controller operatively connected to the isolation switch (118) to control operations of the isolation switch (118), wherein the controller is configured automatically operate the isolation switch (118) to disconnect the battery (114) from the charging circuitry (116) during a welding operation.
The battery-powered welding machine of claim 7, wherein a battery voltage level supplied to the output circuitry is greater than 60 V; wherein the output circuitry includes a chopper (108); and/or wherein the welding operation is shielded metal arc welding or gas tungsten arc welding.
The battery-powered welding machine of any of claims 7 or 8, wherein the controller is configured to automatically operate the isolation switch (118) to disconnect the battery (114) from the charging circuitry (116) based on the welding current level signal, wherein the residual energy preferably is stored in a capacitor, and the bleed circuit includes a resistor for discharging the capacitor.
A battery-powered welding machine, comprising: a battery (114); charging circuitry (116) operatively connected to the battery (114) to charge the battery (114); output circuitry operatively connected to the battery (114) to receive electrical energy from the battery (114) to create a welding arc (106); a first isolation switch connected between battery (114) and the output circuitry to selectively connect and disconnect the battery (114) from the output circuitry; a second isolation switch connected between battery (114) and the charging circuitry (116) to selectively connect and disconnect the battery (114) from the charging circuitry (116); and a controller operatively connected to the first isolation switch to control operations of the first isolation switch, and operatively connected to the second isolation switch to control operations of the second isolation switch, wherein the controller is configured to automatically operate the second isolation switch to disconnect the battery (114) from the charging circuitry (116) during a welding operation, and wherein the controller is further configured to detect a high voltage condition within the output circuitry and, when the high voltage condition is detected, automatically operate the first isolation switch to disconnect the battery (114) from the output circuitry.
The battery-powered welding machine of claim 10, wherein a battery voltage level supplied to the output circuitry is greater than 60 V; wherein the output circuitry includes a chopper (108); and/or wherein the welding operation is shielded metal arc welding or gas tungsten arc welding.
The battery-powered welding machine of any of claims 10 or 11, further comprising a current sensor operatively connected to the controller, wherein the current sensor provides a welding current level signal to the controller, and wherein the controller is configured to automatically operate the second isolation switch to disconnect the battery (114) from the charging circuitry (116) based on the welding current level signal.
The battery-powered welding machine of any of claims 10 to 12, wherein the controller is further configured to detect a high current condition within the output circuitry and, when the high current condition is detected, automatically operate the first isolation switch to disconnect the battery (114) from the output circuitry.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority to U.S. Provisional Patent Application Serial Number 63/706,818 filed on October 14, 2024, the disclosure of which is incorporated herein by reference, to U.S. Non-Provisional Patent Application Serial Number 19/297,084 filed on August 12, 2025, the disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION The present invention relates to welding machines, and in particular to battery-powered welding machines and control of the charging and discharging of the machine's battery or battery pack. A failure within the battery-powered welding machine can result in the full battery voltage level and/or an abnormally high current level being present at the output of the machine, which may be undesirable. Moreover, the welding operation can create undesirable voltage fluctuations at battery charging circuitry. Thus, improvements to battery-powered welding machines that address one or more of such deficiencies would be beneficial. BRIEF SUMMARY OF THE INVENTION The following summary presents a simplified summary in order to provide a basic understanding of some aspects of the devices, systems and/or methods discussed herein. This summary is not an extensive overview of the devices, systems and/or methods discussed herein. It is not intended to identify critical elements or to delineate the scope of such devices, systems and/or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later. In accordance with one aspect of the present invention, provided a battery-powered welding machine. The battery-powered welding machine includes a battery, charging circuitry operatively connected to the battery to charge the battery, and output circuitry operatively connected to the battery to receive electrical energy from the battery to create a welding arc. The output circuitry includes a bleed circuit to selectively discharge residual energy in the output circuitry. An isolation switch is connected between battery and the output circuitry to selectively connect and disconnect the battery from the output circuitry. A control system is operatively connected to the isolation switch to control operations of the isolation switch, and operatively connected to the bleed circuit to control discharging of the residual energy in the output circuitry. The control system is configured to detect a high voltage condition within the output circuitry and, when the high voltage condition is detected, automatically operate the isolation switch to disconnect the battery from the output circuitry, and automatically activate the bleed circuit to discharge the residual energy in the output circuitry. In various embodiments a battery voltage level supplied to the output circuitry is greater than 60 V. In various embodiments the output circuitry includes a chopper. In various embodiments the battery-powered welding machine comprises: a current sensor operatively connected to the control system, wherein the current sensor provides a welding current level signal to the control system, and the control system is configured to detect a high current condition within the output circuitry and, when the high current condition is detected, automatically operate the isolation switch to disconnect the battery from the output circuitry. In various embodiments the battery-powered welding machine comprises: an additional isolation switch that is connected between battery and the charging circuitry to selectively connect and disconnect the battery from the charging circuitry; and a current sensor operatively connected to the control system, wherein the current sensor provides a welding current level signal to the control system, and the control system is configured automatically operate the additional isolation switch to disconnect the battery from the charging circuitry during a welding operation. In various embodiments the welding operation is shielded metal arc welding or gas tungsten arc welding. In various embodiments the control system is configured to automatically operate the additional isolation switch to disconnect the battery from the charging circuitry based on the welding current level signal, In various embodiments the residual energy is stored in a capacitor, and the bleed circuit includes a resistor for discharging the capacitor. In accordance with another aspect of the present invention, provided is a battery-powered welding machine. The battery-powered welding machine includes a battery, charging circuitry operatively connected to the battery to charge the battery, and output circuitry operatively connected to the battery to receive electrical energy from the battery to create a welding arc. The output circuitry includes a bleed circuit to selectively discharge residual energy in the output circuitry. A current sensor generates a welding current level signal. An