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USO05272314A

United States Patent [191

[11]
[45]

Moriguchi et a1.
[54] CONSUMABLE ELECTRODE TYPE D.C.

4,665,299

ARC WELDER

[75] Inventors: Haruo Moriguchi, Itami; Tetsurou
Ikeda, Osaka; Kenzo Danjo, Kizu;
Masahiro Aoyama, l-ligashi; Karino
Kunio, Suita, all of Japan
[73] Assignee: Sansha Electric Manufacturing Co.,

Ltd., Osaka, Japan
[21] Appl. No.: 991,436
[22] Filed:

[30]

Dec. 16, 1992

Foreign Application Priority Data

Dec. 16, 1991 [JP]

Japan ................................ .. 3453356

[51]
[52]

1m.c1.-< .............................................. .. B23K 9/10
u.s.c1. .............. ..
219/130.33;219/130.21

[58]

Field ofSearch .................... ..219/13o.21,13o.31,

[56]

2l9/l30.32, 130.33, 137 PS
References Cited
U.S. PATENT DOCUMENTS
3,792,225 2/1974
4,476,376 10/1984
4,521.672 6/1985

Needham et a1. ............ .. 2l9/l30.2l
Mizuno et al, ........... .. 219/1301]
Fronius ........................ .. 219/130.33

Patent Number:
Date of Patent:

5,272,314
Dec. 21, 1993

5/1987 Iwata ............................ ..2l9/l30.2l

FOREIGN PATENT DOCUMENTS
61-216859

9/1986 Japan .

Primary Examiner-—Clifford C. Shaw
Attorney, Agent, or Firm-Wegner, Cantor, Mueller &

Player
[5 7]

ABSTRACT

A consumable electrode type d.c. arc welder including
an inverter, which is arranged to rectify an a.c. power
from a power supply, once convert a resultant d.c.

power into a high frequency a.c. power by the invertor
and again rectify it to obtain a d.c. power for welding,
and provided with means for detecting a current ?ow

ing through its welding load to certainly discriminate
shortening and arcing states between a welded base
material and a welding electrode rod and controlling
the invertor with a resultant discrimination signal to

reduce its output voltage during the shortening period,
thereby preventing spattering produced by an over-cur
rent.

2 Claims, 3 Drawing Sheets

a

9p 12

-‘—

10p

13
11

.._1.a

Va

33

l

9n

r] [1011 E14
VOLTAGE

DETECT \16

DRIVING
CIRCUIT

21. 1(a) FIG. 3 FIG._ Tw WAN. l k 32 . 1993‘ Sheet 1 of 3- 5.314 FIG.US. Patent Dec. 3 5 /V(4.3 . 4.8.||3 . .272. 1(b) . _|.

21. 2 Dec.2 of 3 5.272.1993 Sheet .314 .US. Patent FIG.

US. 4(f) '1" ---- 5 ' '1 ' ' ' ' 4*‘ ?v ' ?HGV . 4 (a) 0 Sheet 3 of 3 5. 4(d) FIG. 1993 FIG. 4(e)"" """ FIG. 4 (b) FIG. 21. Patent Dec.272. 4 (c) FIG.314 MG FIG.

arc welder. The inverter type do.. arc welder with a con sumable electrode. 1(a) and (b) are waveform diagrams showing variation of the output terminal voltage of a dc. In order to prevent spattering without a larger reac 45 DESCRIPTION OF PREFERRED EMBODIMENT tor.c. especially. 2 is a schematic circuit diagram showing an embodiment of a consumable electrode type do. FIG. MAG welding and MIG welding is effected by supplying the above-mentioned stabilized dc power from the welder to a welding load formed with a continuously fed welding electrode rod and a base material to be welded. 4(a) to (f) are waveform diagrams for explain ing operation of the above embodiment of this inven tion. Therefore. which is provided with novel means for preventing occurrence of undesirable spattering.C. power by the inverter.to an improved invertor type do. are welder. for example. it is considered to detect a shorting period from variation of the output voltage and control the inverter Referring to FIG. undesirable spattering may occur if the dc. ence of the high frequency ripples by using the voltage reactor 8 from positive and negative output terminals 9p across the welding load instead of the voltage between and 9n. recti?ed by an output recti?er 7 of tion is liable to occur and complete prevention of spat diode bridge con?guration. lb and 1c the welder varies originally as shown in FIG. reactor in the output side of the welder for preventing sudden in crease of the welding current. for example.c. The output voltage of the output terminals. the inverter type do arc welder with a consumable electrode /according to this invention is provided with feedback control means for detecting a difference between the output voltage and a predetermined reference voltage and controlling the invertor in accordance with this differ ence to constantly maintain average output voltage and arranged to excessively reduce the average output volt age only during the shorting period of the welding load by detecting the dc. as disclosed in the Japanese patent opening gazette No. power sup plied to the welding load becomes excessive at the time of shorting. Although it is possible to reduce in?u ered through a smoothing and current limiting d. ARC‘ WELDER BACKGROUND OF THE INVENTION This invention relates to a consumable electrode type d. FIG. and then deliv tering is difficult. The positive output terminal 9p is connected output voltage during this period. through input terminals 1a. While consumable electrode type do. More speci?cally. its welding dc.c. power for welding. in a welder of this kind. an a. 3 is a schematic circuit diagram showing an embodiment of an essential portion of the spattering preventing means according to this invention. 1(a) and. are we and. such as bipolar transistors and ?eld effect voltage across the output terminals of the welder in transistors. power. an object of this invention is to provide an improved inverter type d. S6l-2l6859 for example. it should be easy to distinguish therefrom a of diode bridge type. smoothing capacitor 3 and supplied to an inverter 4. then converting it into a high fre quency a. noises are superimposed thereon to make The inverter 4 is composed of semiconductor switching their transitional points unclear.c. power cludes high frequency ripples as shown in FIG. reducing its voltage 2 Accordingly.314 CONSUMABLE ELECTRODE TYPE D.272. It has been a general practice for suppress ing this spattering to provide a large d. be welded. the elements. In practice. smoothed by a shorting period Ts and an arcing period Ta. welding. but it has been a bar to small-sizing and lightweighting of the device.c. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIGS. thereafter. including novel means for effec tively preventing spattering without any troublesome 5 operation as above. similarly repeating shorting and arcing. power supplied from a as above-mentioned on the basis thereof to reduce the commercial power supply of three-phase and 200 volt a. The high fre mutually connected through long cables of 10 to 20 quency power is suitably reduced in voltage by an out meters long. for example. output voltage is stabilized by detecting variation of the tion will be described in more detail below with refer ence to the accompanying drawings in connection with output voltage and controlling a conduction time of the switching elements of the inverter with a resultant de ' These and other features and operation of this inven an embodiment thereof. arc welding such as CO. power is produced by once rectifying and smoothing an input a. 50 of the welder is recti?ed by an input 3-phase recti?er 2 therefore. separating the electrode rod shorted to the base material therefrom to form an arc and. More particularly. The electrode rod 11 and base material 14 connected through a cable Min to a base material 14 to . 1(b) through its high frequency switching operation under since the output terminals and the welding load are control of an inverter driving circuit 5. erroneous detec put transformer 6. it is necessary to change connec through an insulated cable 10p to an electrode rod 11 tion of a voltage detector every time the electrode or 65 continuously supplied from a hoop 12 through a feeding base material is changed and this operation is not only troublesome but also dangerous since conductors of the mechanism 13 and the negative output terminal 9n is detector may break to cause electrical leakage. FIGS. arc welder with a consumable welding electrode. is arranged to effect voltage transformation with a lightweighted inverter compsoed of semi-conductor switching elements without use of a heavy input transformer. In the cited device. tection signal. arc welder including spattering preventing means accord ing to this invention. its average level of the resultant signal.c. however. and produces a high frequency a. SUMMARY OF THE INVENTION This invention is based upon output current detection in view of the above mentioned shortcom of output voltage detection.1 5. which has been developed for making a welding power source device small in size and weight.c. 2.c. for example. In other words. output current of the welder to produce a detection signal and differentiating the detec tion signal to reduce the above-mentioned reference to a suitable level by a small-sized and lightweighted voltage by a predetermined ’ value during a positive output transformer and again rectifying it to produce a dc.c.

the phototransistor 25 conducts and its collector voltage becomes zero. A junc tion of the resistor 26 and phototransistor 25 is con nected through a diode 27 to a relay 28 provided with a normally-open switch 29. the sponsive to the differentiated output from the circuit 36 45 gating signal Gi +Gv applied to the relay 28 becomes as for supplying a command signal through a diode 40 to shown in FIG.c. in cluding a Zener diode 23. the Zener diode 23 is nonconductive and. a resistor 42. the output of the voltage detector 16 is grounded through the Zener diode 23 and light emitting diode 24 and a +B source is grounded through the resistor 26 and phototransistor 25. in FIG. Thus. a light emitting diode 24. On the other hand. 50 The embodiment as described above has been given Next. the circuit 32 includes a current-to-voltage convertor 34 for converting the current detected by the current detector 33 into a voltage. While the out Se and controls a conduction time of the switching put terminal voltage Va of the welder varies as shown elements so that the error signal Se becomes zero. The gating signal generator 39 includes an deleted. Consequently. the Zener diode 23 conducts to energize the light emitting diode 24 and. 4(0) and its positive and negative output levels correspond to the shorting and arcing periods. diodes 27 and 40 constitute an OR gate. is converted into a voltage signal by is supplied to the inverter driving circuit 5 as its control the convertor 34. In the shorting period in which the output voltage is below the predetermined level. means for sup plying an output of said output recti?er to a welding load. power. if the Zener voltage of the Zener diode 43 of the gating signal generator 39 is preset at a little positive value. the tion commanding circuit for spattering prevention. an output recti?er for rectifying an output of said inverter.3 5. 4(d) through the diode 40. which is proportional to the sum of both inputs. a detection signal Si produced by the current detector 33. Accordingly. A consumable electrode do are welder compris ing an input recti?er for rectifying an a. thereby simplifying the device. 4(2). and the light emitting diode 24 and phototransistor 25 form a photocoupler. the operation ampli?er l8 ampli?es (Sr-Sv). exceeds a predetermined level. the collector voltage of the pho totransistor 25. Therefore the signal Gv becomes “0" and the relay 28 is not actuated. As shown. therefore. respectively. 4(}‘) and the above-mentioned problem is the relay 28. decremental correction of the output voltage as same as The relay 28 is driven also by a second correction 35 the above-mentioned voltage-dependent gating signal commanding circuit 32 provided with a current detec tor 33 for detecting a welding current Ia. Since the input of the differentiation circuit 36 also assumes similar variation. a positive reference voltage signal Sr of a prede termined level is also applied through a resistor 20 from a reference voltage setting potentiometer 19. the description will be made on the operation of the ?rst and second correction commanding circuits 22 and 32. 4(a) as described above. Accordingly. reactor 8 increases equivalently to suppress production of spattering. It should be obvi~ ous to those skilled in the art that various modi?cations and changes can be made on this embodiment without leaving the spirit and scope of the invention as de?ned in the apended claims. however. the phototransistor 25 is also noncon only for the purpose of illustration of the invention and does not mean any limitation thereof.c. a phantom block 22 denotes a correc 20 the welding current Ia corresponds to the shorting per ingly. to produce an error signal Se which welding current la. and a gating voltage generator 39 re mentioned voltage-dependent gating signal Gv. the output voltage Va drops and the capacity of the d. a resistor 26 and a diode 27. Although the gating signal Gi is not affected by the high frequency ripple noise of the output signal Va since it is based upon the differentiated value i of the welding current Ia its high level period is a little nar rower than the shorting period. If this problem is allowed as insigni?cant. a differentiation circuit 36 composed of a resistor 37 and a capacitor 38 for differentiating the output voltage of diode 43. The switch 29 connects a negative voltage ofa correction voltage setting potenti ometer 30 through a resistor 31 to the negative input iod and the dropping period corresponds to the arcing period. and feedback control means for detecting an out ductive. the output voltage of the inverter 8 and. An output voltage Va between the output terminals 9p and 9n is detected by a voltage detector 16 and sup plied as a negative output voltage signal Sv through a resistor 17 to a negative input terminal of an operation ampli?er 18 whose positive input terminal is grounded To the negative input terminal of the operation ampli ?er 18. We claim: 1. accordingly. as shown in FIG. a Zener diode 43 ever. which is detected by the voltage detector 16. the input signal of the operation ampli?er 18 becomes (Sr-Sv-Sx) in total and its output error signal Se drops from the aforemen tioned normal value by a value corresponding to the value of Sx. 3. The driving circuit 5 responds to the error signal 5 applied to the differentiation circuit 36. the gating signal Gv becomes a 65 put voltage of said output recti?er and driving said high level “1" and actuates the relay 29 to close the invertor based upon a difference between said voltage switch 28. As shown in FIG. a phototransistor 25. the rising period of In the drawing. Accord 4 operation ampli?er 18. Accordingly. wherein said tiometer 30 is applied as a correction signal Sx to the welder further comprises: .314 form a welding load 15 which produces an arc therebe tween. an ampli?er 35 for Gv. an inverter for converting an output of said input recti ?er into a high frequency a. 4(b) at a delay from the voltage feedback resistor of the operation ampli?er 18. the welding current Ia thereby stabilizing the output voltage. how operation ampli?er 41. that is. by using it together with the above the ampli?er 35. due to nonzero value of the Zener voltage of the Zener amplifying the output voltage of the convertor 34. The gating signal Gi energizes the relay 28 to effect terminal of the operation ampli?er 18. a negative voltage preset by the poten and a predetermined reference voltage. However. The can be omitted. supply power. the Zener diode 43 is put in conduction during the shorting period by the output voltage of the ampli?er 41 through the base emitter path of the transistor 44 to produce a gating signal Gi as shown in FIG. The above-mentioned gating signal Gv is shown in FIG. the circuit 22 for producing the gating signal Gv and a transistor 44 which are connected as shown. reactor 8 Therefore.c. In the arcing period in which the voltage be tween the output terminals 9p and 9n of the welder.272. ampli?ed by the ampli?er 35 and signal. 4(d). due to the dc. its output Ai has a wave form as shown in FIG. 21 denotes a varies as shown in FIG. as a result.

and means for supplying said second gating signal to said correcting means in order to reduce said reference voltage by sald predetermmed value 1" response to a logic sum of said ?rst and second gating signals. . predetermined level.272. An arc welder as set forth in claim 1. 6 correcting means responsive to said ?rst gating signal for reducing said reference voltage by a predeteb 5 welder further comprises: . * 15 20 25 55 60 i i 1 i . means for producing a second gating signal when said a differentiation circuit means for differentiatlng said output voltage of said on1p“ t recti?er is below a detection signal. . and means for producing a ?rst gating signal when an 10 output level of said differentiation circuit means is positive. . . wherein said corresponding thereto.5. . i mmed value- ' I _ l 2. .314 5 means for detecting a current ?owing through said welding load and generating a detection signal .