# US 11,027,355 B2 · Welding power supplies, wire feeders, and systems to measure a weld circuit resistance via communications over the weld circuit

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- Number: US 11,027,355 B2
- Document ID: US11027355B2
- Status: Granted
- Kind: B2
- Application number: 15/454,299
- Filed: 2017-03-09
- Published: 2018-09-13
- Granted: 2021-06-08
- Earliest claimed: 2017-03-09
- Assignees: Illinois Tool Works Inc.
- Applicants: Illinois Tool Works Inc.
- Inventors: Nathan W. Johnson; Brian L. Ott
- Web page: https://patentgrep.com/patent/US11027355B2

## CPC

- B23K 9/1006: {Power supply}
- B23K 9/09: Arrangements or circuits for arc welding with pulsed current or voltage
- B23K 9/0953: {using computing means}
- B23K 9/1043: {characterised by the electric circuit (B23K9/1012 takes precedence)}
- B23K 9/1056: {by using digital means (B23K9/1068 takes precedence)}
- B23K 9/1062: {with computing means}
- 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

Welding power supplies, wire feeders, and systems to measure a weld circuit resistance via communications over the weld circuit are disclosed. An example welding-type power supply includes: a power converter configured to: convert input power to output a current pulse via a weld circuit; and convert the input power to output welding-type power via the weld circuit; a voltage monitor configured to measure a power supply output voltage of the current pulse; a receiver circuit configured to receive, via the weld circuit, a communication comprising a second voltage measurement; and a controller configured to: determine a resistance of a portion of the weld circuit based on the power supply output voltage measurement, the second voltage measurement, and a weld circuit current measurement; and control the power converter to convert the input power to output the welding-type power based on a weld voltage setpoint and the impedance.

## Claims

### Claim 1

A welding-type power supply, comprising:
a power converter configured to:
convert input power to output a current pulse via a weld circuit; and
convert the input power to output welding-type power via the weld circuit;
a voltage monitor configured to measure a first voltage measurement corresponding to a power supply output voltage of the current pulse;
a receiver circuit configured to receive, via the weld circuit, a first communication comprising a second voltage measurement following transmission of current pulse; and
a controller configured to:
determine a resistance of a portion of the weld circuit based on the first voltage measurement, the second voltage measurement, and a weld circuit current measurement; and
control the power converter to convert the input power to output the welding-type power based on a weld voltage setpoint and the resistance.

### Claim 2 (depends on 1)

The welding-type power supply as defined in claim 1, further comprising an auxiliary power circuit configured to output power via the weld circuit.

### Claim 3 (depends on 1)

The welding-type power supply as defined in claim 1, wherein the power converter is configured to generate the current pulse having a predetermined current and a predetermined duration.

### Claim 4 (depends on 1)

The welding-type power supply as defined in claim 1, further comprising a current monitor configured to obtain the weld circuit current measurement in the weld circuit in response to the current pulse.

### Claim 5 (depends on 1)

The welding-type power supply as defined in claim 1, wherein the controller is configured to control the power converter to increase a voltage of the welding-type power from the weld voltage setpoint based on the resistance.

### Claim 6 (depends on 1)

The welding-type power supply as defined in claim 1, wherein the controller is configured to control the power converter to output the current pulse in response to initialization of the welding-type power supply.

### Claim 7 (depends on 1)

The welding-type power supply as defined in claim 1, further comprising a transmitter circuit to transmit a second communication via the weld circuit, the controller configured to control the power converter to output the current pulse in response to the receiver circuit receiving a third communication via the weld circuit.

### Claim 8 (depends on 1)

The welding-type power supply as defined in claim 1, wherein the receiver circuit is configured to receive a second communication via the weld circuit while the welding-type power is flowing through the weld circuit, the second communication including weld voltage feedback information measured at a device remote from the welding-type power supply, and the controller is configured to control the power converter to output the welding-type power according to a voltage feedback loop using the weld voltage feedback information to adjust the modified weld voltage setpoint and to regulate a weld voltage at the remote device based on the adjustment to the modified weld voltage setpoint.

### Claim 9 (depends on 1)

The welding-type power supply as defined in claim 1, wherein the controller is configured to subtract a second impedance associated with a voltage sense lead in the weld circuit to determine the resistance of the portion of the weld circuit.

### Claim 10 (depends on 1)

The welding-type power supply as defined in claim 1, wherein the voltage monitor is configured to sample voltage measurements to determine at least one of a peak voltage, an average voltage or a root-mean-square (RMS) voltage, the controller configured to determine the power supply output voltage as the average voltage or the RMS voltage.