Cordless welding machine and plasma cutter

This application derives priority from U.S. Provisional Patent Application Nos. 60/797,798, filed May 4, 2006, and 60/821,606, filed Aug. 7, 2006.

This specification relates to welding machines and more specifically to cordless welding machines.

Welding machines, or welders, are well known in the prior art.

For example, stick (SMAW) welders melt and join metals by heating them with an arc, between a covered metal electrode and the workpiece. Shielding gas is obtained from the electrode outer coating, often called flux. Filler metal is obtained from the electrode core.

Other welders include the MIG (GMAW) welder, which joins metals by heating them with an arc. The arc is between a continuously fed filler metal (consumable electrode) and the workpiece. Externally supplied gas or gas mixtures provide shielding. Certain flux cored wires (consumable electrode) can be used without external shielding gas.

Typically these welders are connected to AC generators or the AC residential power lines. However, such welders are difficult to move to different places, especially if no nearby source of AC power exists. Furthermore, the typical weight of the machine (without cables, spool and spool gun) is above 45-60 pounds. Typically, the output current of such units at 20% duty cycle is between 1.5 and 1.8 Amps per pound. On, If the batteries are not on board, for example, the unit runs off of automotive batteries (Pb-acid), the user would have to carry an additional heavy component along with the welder.

It is an object to provide a lightweight welding machine.

A cordless welding machine including first and second batteries being connected in parallel, a ground clamp connected to the first and second batteries, and a first welding electrode connected to the first and second batteries, the batteries providing a current output of at least about 40 amps.

Additional features and benefits of the present invention are described, and will be apparent from, the accompanying drawings and the detailed description below.

The accompanying drawings illustrate preferred embodiments according to the practical application of the principles thereof, and in which:

FIG. 1 is a schematic diagram of a cordless stick welding machine according to the invention.

FIG. 2 is a perspective view of a first embodiment of the cordless stick welding machine of FIG. 1 .

FIG. 3 is a perspective view of a second embodiment of the cordless stick welding machine of FIG. 1 .

FIG. 4 is a schematic diagram and partial cross-sectional view of a cordless MIG welding machine according to the invention.

FIG. 5 is a schematic diagram and partial cross-sectional view of a cordless plasma cutter according to the invention.

FIG. 6 is a side view of a power tool engageable with a battery pack usable with a cordless welding machine.

FIG. 7 is a schematic diagram of a cordless MIG welding machine according to the invention, where FIGS. 7A-7D are schematic diagrams for a principal battery circuit, a secondary battery circuit, a voltage supply regulator and a speed control circuit, respectively.

FIG. 8 is a perspective view of an alternate embodiment for a cordless welding machine.

The present invention will now be described more fully hereinafter. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

In FIGS. 1-3 , an exemplary cordless stick welding machine according to the present invention is designated generally by the reference numeral 100 . The welding machine 100 preferably includes a housing 101 . A lid housing 102 may be pivotally attached to housing 101 . A handle 103 may be attached to the housing 101 and/or the lid housing 102 .

Welding machine 100 may have at least two battery packs for power. Preferably, the battery packs can be engaged with power tools 2100 as shown in FIG. 6 . Each battery pack preferably has the same components. Accordingly, the discussion as to battery pack B 1 may apply to battery packs B 2 , B 3 , B 4 as well.

Referring to FIG. 1 , battery pack B 1 has a housing BH, at least one cell BC disposed in housing BH. Cell(s) BC may have a lithium ion chemistry, such as lithium phosphate, lithium manganese, etc. For example, one possible chemistry could be the chemistry disclosed in US Published Application No. 2005/0272214, which is fully hereby incorporated by reference herein.

Preferably, cells BC can output a total voltage of at least about 25 volts and preferably about 36 volts, and a current of about 40 amps.

Cell(s) BC may be disposed two outputs O 1 , O 5 . A switching semiconductor BSR and a current sensor or resistor BR may be disposed between output O 5 and cell(s) BC. A battery control BCC may receive information from the current sensor BR to control the switching semiconductor BSR.

Battery control BCC may also receive other inputs via outputs O 2 , O 3 , O 4 . Preferably, welding machine 100 has a resistor R 11 disposed between outputs O 2 , O 3 and a resistor R 21 disposed between outputs O 3 , O 4 . The values of resistors R 11 , R 21 , as read by battery control BCC, are preferably used by battery control BCC to access the correct pre-programmed settings for proper operation of switching semiconductor BSR.

Persons skilled in the art are referred to US Published Application Nos. 2005/0073282 and 2005/0077878, which are fully incorporated herein by reference, for further information on the components, operation and capabilities of battery pack B 1 .

Outputs O 1 , O 5 may be connected to a diode D 1 and a switch S 1 to activate the Battery Control BCC. As shown in FIG. 1 , a second battery B 2 and a diode D 2 may be connected in parallel. Such parallel combination may be connected in series to the parallel combination of battery B 1 and diode D 1 . Second battery B 2 may be controlled via a switch S 2 , which is preferably physically connected to switch S 1 . Accordingly, a user can close both switches S 1 , S 2 at the same time. The switch is intended to activate the separate Battery Control BCC units and not the main welding current.

An inductor LA may be disposed downstream of the parallel combination of battery B 1 and diode D 1 . Inductor LA may be rated between 50 microhenries to 5 H. A diode DA may be disposed downstream of inductor LA.

As seen in FIG. 1 , a third battery B 3 and a diode D 3 may be connected in parallel. Such parallel combination may be connected in series to the parallel combination of a fourth battery B 4 and diode D 4 .

Batteries B 3 , B 4 may be controlled via switches S 3 , S 4 , respectively, which are preferably physically connected to switch S 1 . Accordingly, a user can close switches S 1 , S 2 , S 3 , S 4 at the same time via one throw.

An inductor LB may be disposed downstream of the parallel combination of battery B 3 and diode D 3 . A diode DB may be disposed downstream of inductor LB. The output of inductor LA and/or diode DA connects with the output of inductor LB and/or diode DB. The combined output is connected to an electrode jack W 0 .

Furthermore, diodes D 2 , D 4 (or if only two battery packs are used, diodes D 1 , D 3 ) are also connected, which in turn are connected to an electrode jack W 1 .

Referring to FIGS. 1-3 , a ground clamp GC can be connected to electrode jack W 1 via a cable GCC. Persons skilled in the art will recognize that ground clamp GC will preferably be attached to workpiece W.

Similarly, a stick clamp SC (electrode holder) can be connected to electrode jack W 0 via a cable SCC. Persons skilled in the art will recognize that an electrode stick S can be held by stick clamp SC. As is well know, when stick S contacts workpiece W, the current sent by welding machine 100 through stick S will cause stick S to melt, thus welding workpiece W.

Persons skilled in the art will recognize that, in the four-battery configuration shown in FIG. 1 , the voltage output will be about 72V and a current output of about 80 amps. In a two-battery configuration (i.e., only battery packs B 1 , B 3 are used), the voltage output will be about 36V and a current output of about 80 amps.

Preferably, all the components of welding machine 100 are disposed during operation within housings 101 and/or 102 , as shown in FIG. 2 . Alternatively, battery packs B 1 , B 3 may be disposed on lid housing 102 , as shown in FIG. 3 . The battery packs can be removably connected to receptacles (disposed inside housing 101 , on top of housing 102 , etc.) as explained in U.S. Pat. No. 6,057,608, which is fully incorporated herein by reference.

Persons skilled in the an will recognize that housings 101 and/or 102 can be designed so that cables GCC, SCC and clamps GC, SC can be stored in housings 101 and/or 102 , allowing the user to carry the entire welding machine 100 via handle 103 . Cord wraps may also be employed to allow external wrapping of welding cables.

With such construction (and the high power-to-weight ratio provided by lithium cell chemistries and/or other chemistries), the total weight of welding machine 100 , excluding cables GCC, SCC and clamps GC, SC, would be between about 8 pounds to about 23 pounds in the two battery pack configuration. In a four battery pack configuration, the total weight of welding machine 100 , excluding cables GCC, SCC and clamps CC, SC, would be between about 12.8 pounds to about 29 pounds.

FIG. 4 illustrates a MIG welding machine 100 ′. Preferably, such machine has the same construction as the stick welding machine 100 described above (and where like numerals refer to like parts), except for one major difference: the welding gun 50 . Gun 50 may have a wire spool 50 S carrying a flexible electrode 50 E, or a channel (not shown) for receiving and exiting such electrode 50 E.

Flexible electrode 50 E may be moved out of gun 50 via a motor 50 M, which may be disposed on or off gun 50 . Persons skilled in the art will recognize that a cable (not shown) may be disposed between welding machine 100 ′ and motor 50 M, to power such motor 50 M. Persons skilled in the art will recognize that a motor power supply (not shown) may be used to vary the speed of motor 50 M (and thus of the exiting electrode 50 E).

Electrode 50 E is ultimately connected to electrode jack W 0 via cable 50 C.

Accordingly, electricity passes between electrode 50 E and workpiece W, the tip of electrode 50 E will melt, welding workpiece W.

Preferably, electrode 50 E has a flux core, allowing flux released from electrode 50 E to cover the weld and prevent oxidation. Gun 50 may have a fan 50 F to spread such gas. Alternatively, gun 50 may receive gas or compressed air from a tank (not shown) disposed off the gun 50 .

Persons skilled in the art will recognize that further controls can be provided to change the output properties of the MIG welding machine 100 ′. For example, a control can be provided to select the specific current or voltage output of MIG welding machine 100 ′. This could be achieved by changing the value of resistors R 11 and/or R 21 , thus informing the battery packs that a new current has been selected. The battery controls BCC would then control the semiconductor switches BSR accordingly.

As before, it is preferable that the entire MIG welding machine 100 ′ be storable into housings 101 and/or 102 . The total weight of welding machine 100 , excluding cables GCC, 50 C, clamp GC, and gun 50 , is preferably between about 8 pounds to about 23 pounds in the two battery pack configuration. In a four battery pack configuration, the total weight of welding machine 100 , excluding cables GCC, 50 C, clamp GC, and gun 50 , may be between about 12.8 pounds to about 29 pounds.

FIG. 5 illustrates a plasma cutting machine 200 , where like parts refer to like numerals. All the teachings of the welding machines shown in FIGS. 1-4 and describe above are incorporated herein by reference. As before, battery pack B 1 is connected to diode D 1 in parallel, with switch S 1 in between battery pack B 1 and diode D 1 .

The output of the battery pack may be connected to electrode Jacks W 0 , W 1 . An inductor L 1 may be disposed between electrode jack W 0 and diode D 1 . A diode D 21 may be disposed between electrode jack W 0 and inductor L 1 .

The output of inductor L 1 and/or diode D 21 may be also connected to a high voltage arc generator AG. Arc generator AG may also be connected to electrode jack W 1 , as well as to output W 2 and battery pack B 1 . The circuitry and function of arc generator AG are well known in the art.

A cutting gun 60 preferably has an electrode 60 E electrically connected to electrode jack W 0 via a cable. Electrode 60 E is substantially surrounded by a ground cap 60 G, which in turn is connected to electrode jack W 2 via a cable. Persons skilled in the art will recognize that the cables connected to jacks W 0 , W 2 may be combined to avoid tangles, etc.

Gun 60 may also have fins and orifices 60 F to direct airflow in a predictable pattern that will assist the plasma arc through the workpiece W. Gun 60 may also have a fan (not shown) for blowing air or gas from a tank 60 GT.

Preferably, gun 60 has a handle 60 H, allowing the user to ergonomically hold gun 60 , and an on/off switch 60 T, which could be connected via electrode jack W to battery pack B 1 . When the user activates switch 60 T, such contact will enable battery pack B 1 to transmit power. When the user deactivates switch 60 T, battery pack B 1 will be disabled.

As before, it is preferably that the entire plasma cutting machine 200 be storable into housings, such as the housings 101 and/or 102 of the previous embodiments. The total weight of plasma cutting machine 200 , excluding cables GCC, the gun cables, clamp GC, and gun 60 , is preferably between about 8 pounds to about 23 pounds.

Persons skilled in the art will recognize that a charger circuit may be disposed in housings 101 and/or 102 to charge battery pack B 1 .

FIGS. 7-8 illustrate another embodiment of a MIG welding machine 100 ′, where like numerals refer to like parts. In this embodiment, the welding machine 100 ′ may have one or more on-board chargers 150 for charging battery packs B 10 . Preferably, such battery packs B 10 are engageable with a power tool, akin to the embodiment shown in FIG. 6 . Persons skilled in the art are referred to US Published Application Nos. 2005/0073282 and 2005/0077878, which are fully incorporated herein by reference for further information on the components, operation and capabilities of battery packs B 10 .

The voltage of each battery pack B 10 may be higher than 18 volts and is preferably between about 28 and about 36 volts.

In the embodiment of FIGS. 7-8 , welding machine 100 ′ preferably uses three battery pack B 10 , each battery pack B 10 having a nominal voltage of about 24 to 36 volts.

One battery pack B 10 is connected to the primary circuit 110 shown in FIG. 7A . The remaining battery packs B 10 are each connected to a secondary circuit 120 shown in FIG. 7B . Persons skilled in the art will recognize that the outputs of circuits 110 and 120 are preferably connected in parallel to electrode jacks W 0 , W 1 .

As shown in FIGS. 7A-7B , each battery pack B 10 is connectable to a charger 150 . Persons skilled in the art will recognize that one of the chargers 150 may be connected to an AC source via a power cord C 10 . The other chargers 150 can be connected in parallel to the power cord C 10 . In this manner, the welding machine 100 ′ is both cordless (as it can run off battery packs B 10 ) and AC-powered (as chargers 150 charge battery packs B 10 , which in turn power the welding machine 100 ′). Users can also remove battery packs B 10 after charging for use with a power tool 2100 .

Primary circuit 110 has relays RL 1 , RL 2 to select whether the battery pack B 10 receives power from charger 150 , or whether battery pack B 10 provides power to electrode jacks W 0 , W 1 . Persons skilled in the art will recognize that battery pack B 10 will provide power to electrode jacks W 0 , W 1 , when the on/off switch S 10 and a gun switch S 11 (disposed, for example, in a gun 50 ) are both activated, activating power supply 130 , which in turn activate relays RL 1 , RL 2 . When on/off switch S 10 or gun switch S 11 are released or moved to the OFF position, power supply 130 will be deactivated, thus deactivating relays RL 1 , RL 2 , and allowing battery pack B 10 to be charged by charger 150 .

FIG. 7C is the schematic circuit for power supply 130 . Basically, battery power B+ is received. Zener diode D 30 limits and regulates the output regulated power RP. Preferably, the regulated power RP is about 12 volts. Persons skilled in the art will recognize that, instead of using a power supply circuit with discrete components, some of the components may be replaced with a voltage regulator integrated circuit.

This regulated power RP may be used to activate the relays RL 1 , RL 2 in the secondary circuits 120 (shown in FIG. 7B ) to select whether the battery pack B 10 receives power from charger 150 , or whether battery pack B 10 provides power to electrode jacks W 0 , W 1 . Persons skilled in the art will recognize that battery pack B 10 will provide power to electrode jacks W 0 , W 1 , when the on/off switch S 10 and a gun switch S 11 (disposed, for example, in a gun 50 ) are both activated, activating power supply 130 , which in turn activate relays RL 1 , RL 2 .

Regulated power RP may also be used to power a gas solenoid used in the welding machine 100 ′, if necessary. In addition, regulated power RP powers the speed control circuit 140 (fully shown in FIG. 7D ) that controls the speed of the motor M feeding the electrode 50 E through a gun 50 .

Diodes D 10 , D 11 are preferably disposed between battery pack B 10 and electrode jack W 0 . This is to prevent a battery pack B 10 from a secondary circuit 120 charging a battery pack B 10 in the primary circuit 110 or another secondary circuit 120 , etc.

Resistors R 12 , R 13 , R 14 , R 15 and R 16 are preferably provided to control the amount of voltage provided via electrode jacks W 0 , W 1 . Preferably all resistors R 14 in primary and secondary circuits 110 , 120 are potentiometers sharing a common shaft, so that when the user rotates the shaft, all resistors R 14 are adjusted in the same amount.

The following list shows the values for the different components in the circuits shown in FIGS. 7A-7D :

C 30 47 microfarads, 50V C 40 0.1 microfarads C 41 0.1 microfarads C 42 0.1 microfarads D 30 12V, 1 W D 40 1N4007 Q 30 TIP31C TO-220 Q 40 1RF1404Z R 12 10 kiloohms, 1% R 13 10 kiloohms, 1% R 14 10 kiloohms potentiometer R 15 11.3 kiloohms, 1% R 16 11.3 kiloohms, 1% R 30 100 ohms, 2 W R 40 2 kiloohms, 5% R 41 10 kiloohms potentiometer R 42 2 kiloohms, 5% R 43 100 ohms, 5% RL 1 Digi-Key Z187-ND, 37 mA RL 2 Digi-Key Z187-ND, 37 mA U 40 LM555

With such arrangement, welding machine 100 ′ would preferably weigh about 21.5 pounds, and about 28 pounds to about 29 pounds with three battery packs B 10 (without cables, spool and spool gun). The current output will be between about 92 amps and about 96 amps, at a 20% duty cycle. This provides for an output current-to-weight ratio of at least about 3.17 amps/pound.

Because of the light weight of welding machine 100 ′, it may be preferable to provide housing 101 with straps 106 , so the user can carry the welding machine 100 ′ as a backpack. Alternatively, housing 101 may have wheels 105 so the user can easily move the welding machine 100 ′.

Typical heavy-duty welders draw power from the AC sources during the welding operation. Typically such welders require 15-20 amps during the welding operation. Accordingly, they are limited to the current available at the moment of welding. Furthermore, such welders require a heavy power cord and/or extension cord to handle such current.

Because welding machine 100 ′ relies on battery packs B 10 to provide the power for the welding operation and only needs AC power to charge the battery packs, the welding machine 100 ′ draws less current than typical welders. In the present configuration, welding machine 100 ′ draws about 5 amps to about 7 amps at 20% duty cycle continuously in order to produce the 90+ amps at 20% duty cycle.

By comparison, typical welding machines draw all the power to perform the welding operation from the AC line. Under North American standards, a typical welder that has a conversion efficiency of 85% would need to draw over 18 amps to supply 90 amps at 20 volts output. Such welder would not be usable with the 15 amp receptacle outlet found in most North American households, requiring such welder to be connected to a special receptacle. In contrast, by using batteries B 10 to provide the necessary power, the welder 100 ′ can be connected to a common 15 amp receptacle.

Furthermore, because of such lower AC current requirements, cord C 10 and/or an extension cord attached to cord C 10 can have a gauge rating lower than the gauge rating used in typical welders. Such gauge rating could be at least 18 AWG or 16 AWG. Persons skilled in the art will recognize that cord C 10 and/or the extension can have a higher gauge rating, such as 14 AWG, 12 AWG, etc.

Persons skilled in the art will recognize that providing a cord C 10 and/or extension with a gauge rating of 18 AWG or higher, the total maximum cord length (without a welding machine shutting down due to the voltage drop due to the cord resistance or without melting the cord) will be at least 100 feet. Preferably, the total maximum cord length for cords having a gauge rating of 16 AWG, 14 AWG or 12 AWG (without a welding machine shutting down due to the voltage drop due to the cord resistance or without melting the cord) being about 192 feet, about 304 feet and about 482 feet, respectively. Accordingly, by using batteries to provide the necessary power, the distance from welder to power source can be greatly increased without using large, heavy, and expensive extension cords.

Welding machine 100 ′ has an output current of 93 amps at 20% duty cycle, and a usable peak output current of about 120 amps to about 135 amps, with an adjustable voltage of about 14 volts and about 24 volts.

Persons skilled in the v will recognize that while battery pack(s) B 10 are preferably removable, the welding machine 100 ′ may have non-removable battery cells instead that can be charged by an on-board charger circuit, such as charger 150 .

Persons skilled in the art will recognize that in all embodiments discussed herein a discharge control is provided in the different battery packs. However, such discharge control can be provided external to the battery pack so that batteries without discharge control can be used to power a cordless welding machine.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.