Dual operator phase control engine driven welder

Abstract

A method and apparatus for providing welding power includes two power sources (first and second), each having an output. A linking circuit selectively connects the power sources in one of an independent mode (such that each is connected to a separate welding output whereby the first welding output is independent of the second welding output) or a combined mode (such that the power sources are connected in parallel and connected to one welding output whereby the outputs of the first power source and second power source are combined). A controller includes a mode selector to allow the user to select between the independent mode and the combined mode. Also, the controller includes a master output magnitude selector, which is a single selector, that controls the magnitude of the output of both power sources when the user has selected the combined mode. The power sources can be operated in a CV or CC mode when independent, or a CC mode when combined. A load compensation circuit compensates for the voltage droop in the output of the generator.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:  
     
         1 . A welding machine comprising: 
 a first power source;    a second power source;    a first welding output;    a second welding output;    a linking circuit, disposed to selectively connect the first and second power sources in an independent mode such that the first power source is connected to the first welding output, and the second power source is connected to the second welding output, whereby the first welding output is independent of the second welding output, and further to selectively connect the first and second power sources in a combined mode such that the first power source output and the second power source output are connected in parallel and connected to the first welding output, whereby the outputs of the first power source and second power source are combined; and    a controller, connected to the linking circuit, wherein the controller includes a mode selector to allow the user to select between the independent mode and the combined mode, and wherein the controller further includes a master output magnitude selector, which is a single selector, that controls the magnitude of the output of both the first power source and the second power source when the user has selected the combined mode.    
     
     
         2 . The welding machine of    claim 1   , wherein the controller further includes a slave output magnitude selector which controls the output of the second power source when the independent mode is selected, and wherein the master output magnitude selector controls the magnitude of the output of the first power source when the independent mode is selected.  
     
     
         3 . The welding machine of    claim 2   , wherein the controller further includes a master magnitude circuit and a slave magnitude circuit, and further wherein the master output magnitude selector provides an input to the master magnitude circuit when the independent mode or the combined mode is selected, and further wherein the master output magnitude selector provides an input to the slave magnitude circuit when the combined mode is selected.  
     
     
         4 . The welding machine of    claim 3   , wherein the slave output magnitude selector provides an input to the slave magnitude circuit when the independent mode is selected.  
     
     
         5 . The welding machine of    claim 4   , wherein the master output magnitude selector includes a master potentiometer, and further wherein the slave output magnitude selector includes a slave potentiometer, and wherein the master and slave potentiometers provide set points.  
     
     
         6 . The welding machine of    claim 1   , wherein the first power source and the second power source receive power from an engine and generator.  
     
     
         7 . The welding machine of    claim 6   , wherein the generator includes a rotor, and wherein the controller includes a load compensation circuit to control the field current in the rotor.  
     
     
         8 . The welding machine of    claim 6   , wherein the first power source and the second power source are phase controlled power sources.  
     
     
         9 . The welding machine of    claim 8   , wherein the first power source and the second power source are full wave, three phase power sources.  
     
     
         10 . The welding machine of    claim 8   , wherein the first power source and the second power source may provide a CC output when in the combined and independent modes, and may provide a CV output when in the independent mode.  
     
     
         11 . The welding machine of    claim 10   , wherein the linking circuit includes a first switch, controlled by the controller, to select one of the CV output and the CC output, and a second switch, controlled by the controller, to select one of the independent and combined modes, wherein the first switch is disposed such that if the CV output is selected the second switch cannot implement the combined mode.  
     
     
         12 . The welding machine of    claim 10   , wherein the controller includes a disable circuit that disables the output when the combined mode is selected and a CV output is selected.  
     
     
         13 . An engine and generator driven welding machine comprising: 
 a first phase controlled power source;    a second phase controlled power source;    a first welding output;    a second welding output;    a linking circuit, disposed to select one of a CC output and a CV output    a controller, connected to the linking circuit, wherein the controller includes an output selector to allow the user to select between the CC output and the CV output.    
     
     
         14 . The welding machine of    claim 13   , wherein the first power source and the second power source are full wave, three phase power sources.  
     
     
         15 . An welding machine comprising: 
 an engine;    a generator connected to and driven by the engine;    a first phase controlled power source, connected to receive power from the generator;    a first welding output, connected to the first power supply;    a controller, connected to the power supply and the generator, wherein the generator includes a rotor, and wherein the controller includes a load compensation circuit to control the field current in the rotor.    
     
     
         16 . The welding machine of    claim 15   , further comprising a second phase controlled power source power source connected to the generator and a second welding output connected to the second power supply.  
     
     
         17 . A method of providing welding power comprising: 
 providing power from a first source;    providing power from a second source;    selectively connecting an independent mode in which the power from the first source is provided to a first output, and connecting the power from the second source is provided to a second output, whereby the first output is independent of the second output;    selectively connecting a combined mode in which the power from the first source is provided to the first output, and connecting the power from the second source to the first output, whereby the outputs of the first power source and second power source are combined; and    controlling the magnitude of both power sources in response to a single user controlled selector, when in the combined mode.    
     
     
         18 . The method of    claim 17   , including the step of controlling the magnitude of the first power source in response to the single user controlled selector and controlling the magnitude of the second power sources in response to a second user controlled selector, when in the independent mode.  
     
     
         19 . The method of    claim 18   , including generating power from an engine and generator, and providing the power to the first and second power sources.  
     
     
         20 . The method of    claim 19   , including compensating for the output load by controlling the field current in a rotor.  
     
     
         21 . The method of    claim 19    including the step of phase controlling the first and second power sources.  
     
     
         22 . The method of    claim 18   , wherein generating includes generating full wave, three phase power.  
     
     
         23 . The method of    claim 18   , including providing one of a CV and a CC output in response to a user selection.  
     
     
         24 . The method of    claim 23   , including disabling the combined mode if the CV output is selected.  
     
     
         25 . A method of providing welding power comprising: 
 generating power and providing it to a first phase controlled power source and a second phase controlled power source;    providing power from the first phase controlled power source;    providing power from the second phase controlled power source;    controlling an output selector to select one of a CC output and a CV output in response to a user input.    
     
     
         26 . A method of providing welding power comprising generating power and providing it to a first phase controlled power source and controlling the generator by compensating for the output load by controlling the field current in a rotor.  
     
     
         27 . A welding machine comprising: 
 a first power source;    a second power source;    a first welding output;    a second welding output;    a linking means for selectively connecting the first and second power sources in an independent mode such that the first power source is connected to the first welding output, and the second power source is connected to the second welding output, whereby the first welding output is independent of the second welding output, and further for selectively connecting the first and second power sources in a combined mode such that the first power source output and the second power source output are connected in parallel and connected to the first welding output, whereby the outputs of the first power source and second power source are combined, wherein the linking means is connected to the first and second power sources; and    a controller means for allowing the user to select between the independent mode and the combined mode, and for allowing the user to select the output magnitude with a single selector that controls the magnitude of the output of both the first power source and the second power source, when the user has selected the combined mode, wherein the controller is connected to the linking circuit and the first and second power sources.    
     
     
         28 . The welding machine of    claim 27   , wherein the controller further includes a slave output magnitude selector means for controlling the output of the second power source when the independent mode is selected.  
     
     
         29 . The welding machine of    claim 27   , wherein the first power source and the second power source receive power from an engine and generator means for generating power.  
     
     
         30 . The welding machine of    claim 29   , wherein the generator means includes a rotor, and wherein the controller means includes a load compensation means for controlling the field current in the rotor and compensating for the output load current.  
     
     
         31 . The welding machine of    claim 8   , further including output means for selecting between a CC output when in the combined and independent modes, and for providing a CV output when in the independent mode.  
     
     
         32 . An engine and generator driven welding machine comprising: 
 a first phase controlled power source;    a second phase controlled power source;    a first welding output;    a second welding output;    a linking means for selecting one of a CC output and a CV output, wherein the linking means is connected to the power sources; and    a controller means for allowing the user to select between the CC output and the CV output, wherein the controller means is connected to the linking means.    
     
     
         33 . An welding machine comprising: 
 an engine;    a generator connected to and driven by the engine;    a power source, connected to receive power from the generator;    a welding output, connected to the first power supply; and    a controller means, for compensating for the output load by controlling the field current in a rotor, wherein the controller means is connected to the power supply and the generator.