Modular power conversion system and method

A power conversion assembly used in combination with a welding power supply, comprising:

• a power magnetics module comprising at least one transformer disposed on a first wind tunnel housing;
• and
• a power electronics module that is separate from and configured to be electrically coupled to the power magnetics module, wherein the power electronics module and the power magnetics module are configured to convert input power to welding power, wherein the power electronics module comprises switching circuitry and one or more heat sinks to remove heat from the switching circuitry, wherein the switching circuitry and the heat sinks are disposed on a second wind tunnel housing configured to be attached to the first wind tunnel housing, wherein parallel sides of the first wind tunnel housing and the second wind tunnel housing are configured to be removably attached together to form an integrated wind tunnel between the parallel sides of the first wind tunnel housing and the second wind tunnel housing;
• wherein the power electronics module is configured to be removed from the welding power supply with the integrated wind tunnel by sliding the power electronics module, the first wind tunnel housing, and the second wind tunnel housing as a single assembly through an opening formed in a sidewall of a chassis of the welding power supply along a lengthwise direction of the parallel sides.