Welding systems with multiple power settings

Abstract

Embodiments of a welding power supply include a housing and a diesel engine disposed in the housing and adapted to output a first power output curve and a second power output curve substantially higher than the first power output curve. The welding power supply also includes a controller coupled to the diesel engine and adapted to control the diesel engine to operate along the first power output curve during a low power operation and to control the diesel engine to operate along the second power output curve during a high power operation.

1 . A welding power supply, comprising:
 an engine having a first nominal setting and a second nominal setting;   control circuitry coupled to the engine and configured to control the engine to operate along a first power output curve at the first nominal setting during a first type of welding process and to operate along a second power output curve higher than the first power output curve at the second nominal setting during a second type of welding process; and   a switch having a first selection for controlling the engine to operate along the first power output curve at the first nominal setting during the first type of welding process, and a second selection for controlling the engine to operate along the second power output curve at the second nominal setting during the second type of welding process.   
     
     
         2 . The welding power supply of  claim 1 , comprising a housing having a control panel with an electrical outlet configured to provide power when the engine is operating at a non-synchronous speed. 
     
     
         3 . The welding power supply of  claim 2 , wherein an output of the electrical outlet is voltage regulated. 
     
     
         4 . The welding power supply of  claim 2 , wherein the electrical outlet is configured to provide power for an auxiliary device. 
     
     
         5 . The welding power supply of  claim 2 , wherein the electrical outlet is configured to provide power for SMAW welding or plasma cutting. 
     
     
         6 . The welding power supply of  claim 1 , comprising a housing having a control panel with the switch. 
     
     
         7 . The welding power supply of  claim 1 , wherein the first and second power output curves comprise voltage-to-amperage curves. 
     
     
         8 . A welding power supply comprising:
 an engine configured to operate along a first power output curve and to operate along a second power output curve higher than the first power output curve, wherein the first and second power output curves comprise voltage-to-amperage curves;   a controller coupled to the engine and configured to control the engine to operate along the first power output curve during a low power operation and to control the engine to operate along the second power output curve during a high power operation; and   a switch having a first selection for controlling the engine to operate along the first power output curve, and a second selection for controlling the engine to operate along the second power output curve.   
     
     
         9 . The welding power supply of  claim 8 , comprising a control panel comprising a receptacle configured to utilize non-synchronous primary power to produce output power when the engine is operating along the second power output curve. 
     
     
         10 . The welding power supply of  claim 9 , wherein the receptacle is protected by a current leakage device. 
     
     
         11 . The welding power supply of  claim 9 , wherein the output power is voltage regulated. 
     
     
         12 . The welding power supply of  claim 9 , wherein the receptacle is configured to provide power for at least one of a light and a grinder. 
     
     
         13 . The welding power supply of  claim 8 , comprising a control panel comprising a power outlet configured to couple to an alternate weld device during the high power operation. 
     
     
         14 . The welding power supply of  claim 8 , wherein the first selection corresponds to a first type of welding process, and the second selection corresponds to a second type of welding process. 
     
     
         15 . A welding power supply, comprising:
 an engine having a potential power output level, a low speed power output setting configured to utilize a first percentage of the potential power output level, and a high speed power output setting configured to utilize a remaining percentage of the potential power output level;   control circuitry coupled to the engine and configured to control the engine to operate at the low speed power output setting during a low power operation and to operate at the high speed power output setting during a high power operation; and   a switch having a first selection for controlling the engine to operate at the low speed power output setting, and a second selection for controlling the engine to operate at the high speed power output setting.   
     
     
         16 . The welding power supply of  claim 15 , wherein the low power operation comprises a SMAW welding operation. 
     
     
         17 . The welding power supply of  claim 15 , comprising a power receptacle configured to provide power for one or more auxiliary tools capable of operating off a non-synchronous speed of the engine. 
     
     
         18 . The welding power supply of  claim 17 , wherein the power receptacle is configured to provide power for at least one of a light and a grinder. 
     
     
         19 . The welding power supply of  claim 15 , wherein the high power operation comprises a welding operation utilizing a large diameter wire and a high feed speed. 
     
     
         20 . The welding power supply of  claim 15 , wherein the first selection corresponds to a first type of welding process, and the second selection corresponds to a second type of welding process.