# US 12,005,533 B2 · Systems and methods for automatic range control > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,005,533 B2 - Document ID: US12005533B2 - Status: Granted - Kind: B2 - Application number: 15/720,012 - Filed: 2017-09-29 - Published: 2019-04-04 - Granted: 2024-06-11 - Earliest claimed: 2017-09-29 - Assignees: Illinois Tool Works Inc. - Applicants: Illinois Tool Works Inc. - Inventors: Nathan Joe Jochman - Web page: https://patentgrep.com/patent/US12005533B2 ## CPC - B23K 9/1062: {with computing means} - B23K 9/095: Monitoring or automatic control of welding parameters - B23K 9/10: Other electric circuits therefor; Protective circuits; Remote controls - B23K 9/1012: {characterised by parts of the process} - B23K 9/1043: {characterised by the electric circuit (B23K9/1012 takes precedence)} - B23K 10/006: {Control circuits therefor} - B23K 10/02: Plasma welding - 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 An output control for a welding-type power supply includes a first contactor associated with a first weld output range. A second contactor associated with a second weld output range. An input device configured to select a weld output value from the first weld output range and the second weld output range. A control circuit configured to control the first contactor and the second contactor based on a selected weld output value, and adjust a weld output based on the selected weld output value of the input device. ## Claims ### Claim 1 An output control for a welding-type power supply comprising: a reactor comprising a winding having a first end, a second end, and a plurality of turns between the first end and the second end; a first contactor associated with a first weld output range configured to tap into the reactor at a first position of the winding to define a first set of turns between the first end and the first position; a second contactor associated with a second weld output range configured to tap into the reactor at a second position of the winding to define a second set of turns between the first end and the second position, wherein the second set of turns includes the first set of turns, and wherein the first weld output range overlaps with the second weld output range to define a transition range; an input device comprising a single knob configured to select a weld output value from the first weld output range and the second weld output range; and a control circuit configured to: control each of the first contactor and the second contactor automatically based on a selected weld output value from the single knob; determine whether the weld output value corresponds to the first weld output range or the second weld output range to yield determined weld output range; and adjust a weld output within the determined weld output range by adjusting a field current thereof to achieve the selected weld output value of the input device. ### Claim 2 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to engage the second contactor and disengage the first contactor in response to the selected weld output value corresponding to the second weld output range. ### Claim 3 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to transition from the first weld output range to the second weld output range when the selected weld output value is within the second weld output range. ### Claim 4 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to transition from the second weld output range to the first weld output range when the selected weld output value is within the first weld output range. ### Claim 5 (depends on 1) The output control as defined in claim 1, further comprising a display to provide an indication of a value of the weld output based on an engaged contactor and a selected weld output value. ### Claim 6 (depends on 1) The output control as defined in claim 1, further comprising a third contactor associated with a third weld output range configured to tap into the reactor at a third position on the winding, the control circuit further configured to: control the third contactor based on the selected weld output value; and adjust a weld output within the third weld output range based on the selected weld output value. ### Claim 7 (depends on 6) The output control as defined in claim 6, wherein the second weld output range overlaps the third weld output range. ### Claim 8 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to control the weld output to continuously increase through the first weld output and the second weld output ranges. ### Claim 9 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to change the field current of an engine-driven generator. ### Claim 10 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to: increase the weld output by controlling the first and second contactors and increase the field current; and decrease the weld output by controlling the first and second contactors and decrease the field current. ### Claim 11 (depends on 1) The output control of claim 1, wherein the control circuit is configured to control the weld output to continuously increase through the first weld output range and the second weld output range. ### Claim 12 (depends on 1) The output control of claim 1, wherein the control circuit is configured to control the weld output to increase linearly through the first weld output range and the second weld output range. ### Claim 13 (depends on 1) The output control as defined in claim 1, wherein the control circuit is configured to transition between the first contactor and the second contactor at the transition range. ### Claim 14 (depends on 13) The output control of claim 13, wherein the control circuit is configured to adjust a field current associated with the first contactor or the second contactor during transition between the first contactor and the second contactor. ### Claim 15 (depends on 14) The output control of claim 14, wherein the control circuit is configured to adjust a field current associated with the second contactor during transition from the first contactor to the second contactor. ### Claim 16 (depends on 14) The output control of claim 14, wherein the control circuit is configured to adjust a field current associated with the second contactor during transition from the second contactor to the first contactor. ### Claim 17 (depends on 1) The output control of claim 1, wherein the first weld output range is 50 to 80 amps and the second weld output range is 70 to 110 amps. ### Claim 18 An output control for a welding-type power supply comprising: a reactor comprising a winding having a first end, a second end, and a plurality of turns between the first end and the second end; a first contactor associated with a first welding current range and configured to tap into the reactor at a first position of the winding to define a first set of turns between the first end and the first position; a second contactor associated with a second welding current range and configured to tap into the reactor at a second position of the winding to define a second set of turns between the first end and the second position, wherein the second set of turns includes the first set of turns, and wherein the first welding current range overlaps the second welding current to define a transition range; an input device comprising a single knob configured to select a weld output value from the first welding current range and the second welding current range; and a control circuit configured to: control each of the first contactor and the second contactor automatically based on a selected weld output value from the single knob; determine whether the weld output value corresponds to the first weld output range or the second weld output range; transition between the first contactor and the second contactor at the transition range when the output value corresponds to the second weld output range; adjust a field current associated with the second weld output range during said transition between the first contactor and the second contactor at the transition range; and adjust a weld output based on the selected weld output value of the input device. ### Claim 19 (depends on 18) The output control as defined in claim 18, further comprising a third contactor associated with a third welding current range configured to tap into the reactor at a third position of the winding that is associated with a third set of turns within said plurality of turns that overlaps with said second set of turns, the control circuit further configured to: control the third contactor based on the selected weld output value; and adjust a weld output within the third welding current range based on the selected weld output value.