Hybrid welding supply
A power source for an implement used to perform a welding or cutting operation, the power source including an engine component including a generator and a rectifier electrically connected to the generator and adapted to convert alternating current provided by the generator to a direct current, the engine component being switchable between an on condition and an off condition; at least one battery, wherein the engine component and at least one battery are electrically connected to a chopper bus; and a controller in communication with the generator, chopper bus, operation chopper, and the charging switch; an auxiliary power converter including at least one of a DC to AC and a DC to DC converter, the auxiliary power converter being electrically connected to the operation chopper and the at least one battery.
1. A power source for an implement performing a welding or cutting operation comprising:
an engine component including a field-controlled generator, the engine component being switchable between an on condition and an off condition;
a rectifier electrically connected to the field-controlled generator, wherein the rectifier converts alternating current provided by the field-controlled generator into a direct current;
at least one battery, wherein:
the engine component and at least one battery are electrically connected to a chopper bus,
the chopper bus is connected across the rectifier, and
a voltage droop of the chopper bus is controlled by field control of the field-controlled generator;
a charging chopper electrically connected to the field-controlled generator and the at least one battery, wherein the charging chopper provides a selected power to the at least one battery;
a battery boost converter electrically connecting the at least one battery to the chopper bus;
an auxiliary power converter being electrically connected to the chopper bus, the auxiliary power converter including a DC to DC converter;
a controller in communication with the field-controlled generator, auxiliary power converter and the battery boost converter, wherein the controller selectively varies power output from the engine component, and the at least one battery via the chopper bus and battery boost converter, to provide power sufficient to perform the operation; and
a user interface for receiving a welding output preset, wherein the user interface is powered, when the engine component is in the off condition, by the at least one battery through the battery boost converter, the chopper bus, and the DC to DC converter.
2. The power source of claim 1 , wherein the auxiliary power converter is connected to a peripheral, wherein the auxiliary power converter provides power to the peripheral when the engine component is in the off condition.
3. The power source of claim 1 , wherein the user interface includes an output, the output including a display.
4. The power source of claim 3 , wherein the user interface further includes an input.
5. The power source of claim 1 , wherein the user interface includes a contribution input allowing manual adjustment of a power balance between the engine component and the at least one battery, wherein, based on the contribution input, the user interface signals the controller to vary the power contribution of the engine component relative to the at least one battery.
6. The power source of claim 2 , wherein the auxiliary power converter includes a DC to AC converter.
7. The power source of claim 6 further comprising an outlet, the outlet being electrically connected to the auxiliary power converter.
8. The power source of claim 1 , wherein the at least one battery is adapted to provide the power output sufficient to perform the operation when the engine component is in the off condition.
9. The power source of claim 1 , wherein the charging chopper includes a buck regulator that provides a selected charging voltage to the at least one battery.
10. The power source of claim 9 wherein the controller deactivates power output to the implement when the charging chopper is connected to the at least one battery.
11. The power source of claim 9 further comprising a battery monitor in communication with the controller and the at least one battery, wherein the battery monitor is adapted to determine the charge level of the at least one battery and report the charge level to the controller.
12. The power source of claim 1 wherein the battery boost converter is operable to increase power provided by the engine component with power from the at least one battery.
13. The power source of claim 1 , wherein the user interface includes a quiet mode selection to operate the engine component in a quiet mode, wherein the engine component is operated to produce a selected noise level.
14. The power source of claim 13 , wherein the selected noise level is less than 90 dB.
15. The power source of claim 13 , wherein the selected noise level corresponds to operating the engine component at a selected revolutions per minute.
16. A power source for an implement performing a welding or cutting operation comprising:
an engine component including a field-controlled generator, the engine component being switchable between an on condition and an off condition;
a rectifier electrically connected to the field-controlled generator, wherein the rectifier converts alternating current provided by the field-controlled generator into a direct current;
at least one battery, wherein the engine component and at least one battery are electrically connected to a chopper bus, wherein a voltage droop of the chopper bus is controlled by field control of the field-controlled generator;
a charging chopper electrically connected to the field-controlled generator and the at least one battery, wherein the charging chopper provides a selected power to the at least one battery;
a battery boost converter electrically connected to the at least one battery;
an auxiliary power converter being electrically connected to the chopper bus, the auxiliary power converter including a DC to DC converter;
a controller in communication with the field-controlled generator, auxiliary power converter and the battery boost converter, wherein the controller selectively varies power output from the engine component and the at least one battery via the chopper bus and battery boost converter to provide power sufficient to perform the operation; and
a user interface for receiving a welding output preset, wherein the user interface is in communication with the controller, and wherein the user interface includes a contribution input allowing manual adjustment of a power balance between the engine component and the at least one battery, wherein, based on the contribution input, the user interface signals the controller to vary the power contribution of the engine component relative to the at least one battery,
wherein the user interface is powered, when the engine component is in the off condition, by the at least one battery through the battery boost converter, the chopper bus, and the DC to DC converter.
17. The power source of claim 16 further comprising a housing, wherein the auxiliary power converter is electrically connected to at least one outlet supported on the housing.
18. The power source of claim 16 , wherein the user interface includes an input and an output.
19. The power source of claim 18 , wherein the user interface includes a touch screen display.
20. The power source of claim 19 , wherein the input includes at least one button.
21. The power source of claim 18 , wherein the output includes a bar graph contribution display that visually displays the relative power contribution of the engine component and the at least one battery.
22. The power source of claim 16 , wherein the chopper bus is connected directly across the rectifier.