Two-phase transformer and welding circuit therefor

Abstract

An apparatus for converting three-phase electrical energy into direct current includes Scott-connected transformers with oppositely biased SCRs connected in parallel to two of three input terminals. The SCRs are controlled so that they fire in alternate and rotating sequence between the two input terminals. The secondary output voltages of four terminals are rectified so that the common rectified output voltage is a substantially DC voltage with a minimum ripple. The secondary output terminals are aligned in a common plane and are connected to deformable, tapered leads. The rectifiers are connected between the deformable leads and to a common slotted, conductive plate which is connected to a welding electrode. A center tap from each of the secondary windings is connected to another welding electrode. The deformable tapered leads and the slotted conductive plate provide an equal resistive path for pairs of rectifiers for each secondary output to equalize the current flow through the two sets of diodes.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
       1. In a welding apparatus having Scott-connected transformers, three primary input terminals which are adapted to be connected to a three-phase power supply and four secondary output leads with which are connected to a first electrode through wafer diode assemblies, the transformer further having a center tap output lead from each of the secondary coils, which center tap output lead is connected to a second welding electrode, whereby a DC circuit is made through the first and second electrodes, the improvement comprising: all of the four secondary output leads formed in a relatively flat configuration with top and bottom surfaces of greater extent than other surfaces of said leads, at least the top surfaces of each of said output leads lie entirely in a common plane;   deformable leads formed of multiple laminated straps of conductive material connected between each of the output leads and the diodes for firmly supporting the diodes;   a common conductor plate member of relatively flat configuration having a surface of greatest extent lying entirely in a plane parallel to the common plane of the output leads; and   means clamping the diode assemblies under pressure between the common conductor plate and the deformable leads so that the leads deformably respond to any variation in thickness of the diodes as the diodes are secured in place so that equal pressure can be applied to each diode.   
     
     
       2. A welding apparatus according to claim 1 wherein first and second diodes are provided between each deformable lead and the common conductor plate; the deformable leads have a first thickness between the output leads and a point spaced therefrom beyond the first diode and a second thickness substantially less than the first thickness between the point and the outer ends of the leads, the second diode being mounted to the deformable lead at an area which includes the second thickness whereby the deformable leads are tapered in accordance with the distance from the secondary output leads to provide substantially equal resistive paths for each set of diodes. 
     
     
       3. A welding apparatus according to claim 2 wherein the second thickness is approximately half of the first thickness. 
     
     
       4. A welding apparatus according to claim 2 wherein the common conductor plate is slotted between the two sets of diodes. 
     
     
       5. In an apparatus for converting three-phase alternating current to direct current, said apparatus including transformers having Scott-connected primary windings with three input terminals for connection to a three-phase power supply, a pair of secondary windings with output terminals at opposite ends thereof, and a common center tap output terminal connected to the center of each secondary winding; a common conductor means for connecting together all of the secondary output terminals; and means for rectifying the output from each secondary output terminal; the improvement which comprises: control means for regulating the voltage applied to a first and second of the primary input terminals such that voltage applied to the first and second terminals alternates each 90° interval throughout the electrical cycle in such a manner that the current between each output terminal and the center tap output in the secondary windings conducts successively through each of the four output terminals during successive 90° intervals of the electrical cycle;   the first input terminal being connected to one primary winding and the second input terminal being connected to the other primary winding;   whereby the rectified output current between the common conductor means and the common center tap output terminal is substantially conductive throughout the entire electrical cycle and the ripple effect in the output is minimized.   
     
     
       6. An apparatus according to claim 5 wherein the control means includes first and second oppositely biased gated rectifying means connected in parallel to the first input terminal, and third and fourth oppositely biased gated rectifying means connected in parallel to the second input terminal; and the control means include means for gating the first rectifying means during a first time interval, means for gating the third rectifying means during a second time interval, means for gating the second rectifying means during a third time interval and means for gating a fourth rectifying means during a fourth time interval. 
     
     
       7. An apparatus according to claim 6 wherein the gated rectifying means are silicon controlled rectifiers. 
     
     
       8. An apparatus according to claim 7 and further comprising deformable leads connected between each of the output leads; the output terminals are formed in a relatively flat configuration with top and bottom surfaces of greater extent than other surfaces of said terminals, at least the top surfaces of each of said output terminals are all positioned entirely in a common plane;   a common conductor plate member of relatively flat configuration having a surface of greatest extent lying entirely in a plane parallel to the common plane of the output terminals; and   means mounting the diodes under pressure between the common conductor plate and the deformable leads so that the leads deformably respond to any variations in thickness of the diodes as the diodes are secured in place so that equal pressure can be applied to each diode.   
     
     
       9. An apparatus according to claim 8 wherein first and second diodes are connected between each deformable lead and the common conductor plate member; and the deformable leads have a first thickness adjacent to the secondary output terminals at the first diodes and a second thickness substantially less than the first thickness remote from the secondary output terminal at the second diodes; whereby equal resistive paths are provided for the first and second diodes.   
     
     
       10. An apparatus according to claim 9 wherein the common conductor plate member is slotted between the two sets of diodes, thereby further equalizing the resistive paths for each set of diodes. 
     
     
       11. A welding apparatus comprising the apparatus according to claim 10 and further comprising a first welding electrode electrically coupled to the common conductor plate member, and a second welding electrode electrically coupled to the center tap terminals. 
     
     
       12. In a welding apparatus having Scott-connected transformers with three primary input terminals which are adapted to be connected to a three-phase power supply and four secondary output leads which are connected to a first electrode through diode assemblies, the transformer further having a center tap output lead from each of the secondary coils, which lead is connected to a second welding electrode, whereby a DC circuit is made through the first and second electrodes, the improvement comprising: at least two of the four secondary output leads are formed in a relatively flat configuration with top and bottom surfaces of greater extent than other surfaces of said leads, at least the top surfaces of each of the two output leads lie entirely in a common plane;   deformable leads connected between each of the output leads and the diodes for firmly supporting the diodes, the deformable leads comprising multiple straps of conductive material which are laminated together;   a common conductor plate member of relatively flat configuration having a surface of greatest extent lying entirely in a plane parallel to the common plane of the two output leads; and   means clamping the diode assemblies under pressure between the common conductor plate and the deformable leads so that the leads deformably respond to any variation in thickness of the diodes as the diodes are secured in place so that equal pressure can be applied to each diode. .Iadd. 13. In a welding apparatus having a transformer with primary input terminals which are adapted to be connected to a power supply, at least two secondary output leads which are connected to a first electrode, the secondary output leads being formed in a relatively flat configuration with top and bottom surfaces of greater extent than other surfaces of said leads, at least one of the top and bottom surfaces of said secondary output leads lies entirely in a common plane; a center tap output lead from the transformer connected to a second electrode whereby an electrical circuit is made between said first and second electrodes; and a diode assembly between the secondary output leads and the first electrode to convert the output of the secondary output leads to direct current; the improvement in the diode assembly which comprises:   a plurality of diodes each of which having two relatively flat sides in parallel relationship;   a common conductor plate of relatively flat configuration having a surface of greatest extent lying entirely in a plane parallel to the common plane of the secondary output leads and in contact with one flat side of each of said diodes;   a plurality of deformable leads, each of said deformable leads being in contact with a second flat side of one of said diodes, each of the deformable leads comprising multiple straps of conductive material which are laminated together; and   means clamping said diodes between said deformable leads and said common conductor plate to apply equal pressure to each of said diodes. .Iaddend..Iadd. 14. A welding apparatus according to claim 13 wherein said deformable leads are each secured to one of said secondary output leads. .Iaddend.