# US 10,864,592 B2 · Welding system having an auxiliary charger > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,864,592 B2 - Document ID: US10864592B2 - Status: Granted - Kind: B2 - Application number: 13/841,626 - Filed: 2013-03-15 - Published: 2014-09-18 - Granted: 2020-12-15 - Earliest claimed: 2013-03-15 - Assignees: Illinois Tool Works Inc. - Applicants: Illinois Tool Works Inc. - Inventors: James F. Ulrich; Allen Raymond Sykes - Web page: https://patentgrep.com/patent/US10864592B2 ## CPC - B23K 9/1075: {Parallel power supply, i.e. multiple power supplies or multiple inverters supplying a single arc or welding current} - B23K 9/1006: {Power supply} - B23K 9/1081: {Arc welding by means of accumulated energy} - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM ## Abstract A welding system includes an engine configured to drive a generator to produce a first power output. The welding system also includes a battery configured to discharge energy to produce a second power output. In addition, the welding system includes an auxiliary charger coupled to the battery and the generator. The auxiliary charger is configured to maintain a float charge of the battery when the first and second power outputs are reduced from a base load. ## Claims ### Claim 1 A welding system, comprising: an engine configured to drive a generator; a weld power converter electrically coupled to the generator, wherein the weld power converter is configured to produce a first power output; a battery circuit comprising an auxiliary charger, a battery, and a battery power converter, wherein the battery circuit is electrically coupled to the generator in parallel with the weld power converter, wherein the battery is configured to discharge energy to produce a second power output, and wherein the battery power converter is configured to discharge energy to produce a third power output; and a controller configured to: receive a first input from one or more sensors, the first input comprising a power level of the first power output; receive a second input from one or more sensors, the second input comprising a power level of the second power output; receive a third input from one or more sensors, the third input comprising a power level of the third power output, wherein the first input and the third input comprise the hybrid power output; and based on a reduction of the first power output or the third power output by a predetermined amount, the controller is configured to: select an energy source of a plurality of energy sources to provide power to the auxiliary charger, wherein the auxiliary charger is electrically coupled to the energy source that is separate from the welding system generator; and control the energy source to provide power to the auxiliary charger to provide a float charge of the battery using the power received from the energy source. ### Claim 2 (depends on 1) The welding system of claim 1, wherein the auxiliary charger receives power from the generator and to maintain the float charge of the battery using the power received from the generator. ### Claim 3 (depends on 1) The welding system of claim 1, wherein the energy source comprises an alternator of the engine, and wherein the auxiliary charger receives a 12-volt signal from the alternator of the engine when the engine idles. ### Claim 4 (depends on 1) The welding system of claim 1, wherein the energy source comprises a utility power source, and wherein the auxiliary charger receives power from the utility power source and to maintain the float charge of the battery using the power received from the utility power source. ### Claim 5 (depends on 1) The welding system of claim 1, wherein the energy source comprises an electric system of a work vehicle, and wherein the auxiliary charger receives power from the electric system of the work vehicle and to maintain the float charge of the battery using the power received from the electric system. ### Claim 6 (depends on 5) The welding system of claim 5, wherein the work vehicle comprises a utility truck. ### Claim 7 (depends on 1) The hybrid welding power supply unit of claim 1, wherein the predetermined amount is greater than 10 percent. ### Claim 8 (depends on 1) The hybrid welding power supply unit of claim 1, wherein the auxiliary charger charges the battery via a battery charging cycle comprising a constant current stage, a constant voltage stage, and a float charging stage, wherein the float charging stage comprises charging the battery at a constant voltage to charge the battery to capacity over a period of time. ### Claim 9 A hybrid welding power supply unit, comprising: a weld power converter electrically coupled to a generator driven by an engine; a battery circuit comprising an auxiliary charger, a battery, and a battery power converter, wherein the battery circuit is electrically coupled to the generator in parallel with the weld power converter; and a controller configured to: receive a first input from one or more sensors, the input comprising a power level of the weld power converter; receive a second input from one or more sensors, the input comprising a power level of the battery power converter output; and based on a reduction of power of only one of the first power output or the third power output by a predetermined amount, the controller is configured to: select an energy source of a plurality of energy sources to provide power to the auxiliary charger, wherein the auxiliary charger is electrically coupled to the energy source that is separate from the hybrid welding power supply unit; and control the energy source to provide power to the auxiliary charger to provide a float charge of the battery using the power received from the energy source. ### Claim 10 (depends on 9) The hybrid welding power supply unit of claim 9, wherein the auxiliary charger receives power from a generator of an engine-generator unit of the hybrid welding power supply unit and to maintain the float charge of the battery using the power received from the generator. ### Claim 11 (depends on 9) The hybrid welding power supply unit of claim 9, wherein the energy source comprises a utility power source, and wherein the auxiliary charger receives power from the utility power source and to maintain the float charge of the battery using the power received from the utility power source. ### Claim 12 (depends on 9) The hybrid welding power supply unit of claim 9, wherein the energy source comprises an electric system of a work vehicle, and wherein the auxiliary charger receives receive power from the electric system of the work vehicle and to maintain the float charge of the battery using the power received from the electric system. ### Claim 13 A method, comprising: utilizing an auxiliary charger of a hybrid welding power supply unit to charge a battery of the hybrid welding power supply unit, wherein the auxiliary charger is electrically coupled between the battery and a generator of an engine-generator unit of the hybrid welding power supply unit, wherein the auxiliary charger, the battery, and a battery power converter are electrically coupled to the engine-generator unit in parallel with a weld power converter; receiving a first input from one or more sensors, the input comprising a power level of the weld power converter output; receiving a second input from one or more sensors, the input comprising a power level of the battery power converter output; monitoring for a reduction of the weld power converter output or the battery power converter output; and based on the reduction of the weld power converter output or the battery power converter output: selecting an energy source of a plurality of energy sources to provide power to the auxiliary charger, wherein the auxiliary charger is electrically coupled to the energy source that is separate from the hybrid welding power supply unit; and controlling the energy source to provide power to the auxiliary charger to provide a float charge of the battery using the power received from the energy source. ### Claim 14 (depends on 13) The method of claim 13, comprising maintaining the float charge of the battery using power received from the generator of the engine-generator unit of the hybrid welding power supply unit. ### Claim 15 (depends on 9) The hybrid welding power supply unit of claim 9, wherein the energy source comprises an alternator of the engine. ### Claim 16 (depends on 15) The hybrid welding power supply unit of claim 15, wherein the auxiliary charger is configured to receive a 12-volt signal from the alternator of the engine when an engine of the engine-generator unit idles. ### Claim 17 (depends on 13) The method of claim 13, comprising maintaining the float charge of the battery using power received from an alternator of the engine.