Abstract: A weld control system, supplied by a polyphase voltage source, consists of an isolation contactor supplying power to separate single phase weld controllers. The single phase weld control systems have their separate power modules combined into a single power module assembly for more efficient cooling and electrical interfacing. The single power module consists of a semiconductor switch for each phase of the polyphase voltage source and a single chiller plate for mounting and cooling the switches. The chiller plate functions as a heat sink and is machined to create a series of channels that become coupled together to form a continuous tube having a single input and a single output for a coolant liquid. A SCR pair, housed in a single package in a back-to-back configuration having an isolated base construction. The base has good thermal conductivity between the heat generating semiconductors in the package and the base.

Abstract: A programmable data link module is used on a time division multiplex data bus. The module receives data from the data bus during a selected time slot for a selected number of frames. The data link module includes an input circuit for generating a data output signal data to the data bus in response to input signals from an input device coupled to the module. The input circuit includes a data bus integrity checker for determining whether the data bus is intact. A test signal is sent by a master clock source to the data link module and if it is properly received, the integrity checker will permit the data link module to received data signals from the data bus.

Abstract: A weld controller is coupled to a communications network which has an operator interface unit for monitoring and controlling the weld controller and other weld controllers on the network. A common database in the operator interface unit is accessible across the communication network by the weld controller regardless of the data structure of the database. The weld controller can use the database to obtain different weld schedules, duplicate its own weld schedule to provide for easy replacement, and as a data storage for its operating parameters and values. The weld controller has a dual communications port that allows for a variety of operator interface configurations. Data from weld controller can be accessed by the operator interface controller based upon the weld controller's individual data structure and type through embedded objects resident in the operator interface's operating system and program.

Abstract: A process of manufacturing an insulator having a central core and an insulating body fitted tightly around the central core includes interposing a flexible coating layer between a part of the central core and the insulating body. The flexible coating layer fills in shrinkage cavities and compensates for a retraction effect caused by injected material used in forming the insulating body. The insulating body is achieved by overmolding the central core previously coated with the flexible coating layer with an injected insulating resin such as a thermoplastic or thermosetting resin. The insulator could be used as a capacitive divider or bushing insulator.

Abstract: A programmable data link module (32) for use in a time division multiplexing control system (30) having a plurality of modules interconnected by a bus (40) for passing control signals between data link modules on a serial multiplex basis. Each module includes an integrated circuit (80) having signal conditioning circuits (180, 186 and 188) including a programmable hysteresis circuit (126), a power on reset delay circuit (190), a safety input inhibit circuit (220), a clock loss detect circuit (240), a safety output protection circuit (262), a data verifier (260), a polarity selector for a third output terminal (350), an input synchronizer (182 and 184), a combined mode/sync output terminal (110), a multiplex clock output terminal (108), a programming circuit (232) for accepting programming over the clock bus (44) and data bus (46), input/output word extender circuits (104, 106), a high voltage protection circuit (420) including a transistor (600) and a data bus integrity checker (630).

Abstract: A weld control system, supplied by a polyphase voltage source, consists of multiple and separate single phase weld controllers. The single phase weld control systems have their separate power modules combined into a single power module assembly for more efficient cooling and electrical interfacing. The single power module consists of a semiconductor switch for each phase of the polyphase voltage source and a single chiller plate for mounting and cooling the switches. The chiller plate functions as a heat sink and is machined to create a series of channels that become coupled together to form a continuous tube having a single input and a single output for a coolant liquid. A SCR pair, housed in a single package in a back-to-back configuration having an isolated base construction. The base has good thermal conductivity between the heat generating semiconductors in the package and the base.

Abstract: A programmable data link module is used on a time division multiplex data bus and includes a system master clock signal. The module is functional as an input device, an output device, or both as an input and output device. It receives data from the data bus during a selected time slot for a selected number of frames to control output devices connected to it. The data link module includes a clock loss signal for generating an inhibit signal when a loss of the master clock signal is detected. The inhibit signal will prevent any changes to the state of the output device during the duration of the loss of the master clock signal.

Abstract: A non-ferrous current sensor is used to continuously measure the charging current magnitude in step-graded foil and paper insulation systems and capacitive insulation systems used on high voltage measurement and control apparatus such as instrument transformers and on the condenser bushings of power transformers and circuit breakers. The low voltage measured signal is conditioned by an electronic circuit that modulates a DC signal in a system current control loop to provide continuous remote monitoring and alarm functions. Remote power is supplied to the sensor and conversion circuits through the current loop. The sensor detects changes in the charging current through the insulation ground conductor, indicating the degradation of the dielectric properties between the foil layers. The sensor and associated electronic circuitry are enclosed in a housing adaptable to be used with a capacitance tap common to high voltage measurement and control apparatus.

Abstract: A non-ferrous current sensor is used to continuously measure the charging current magnitude in step-graded foil and paper insulation systems and capacitive insulation systems used on high voltage measurement and control apparatus such as instrument transformers and on the condenser bushings of power transformers and circuit breakers. The low voltage measured signal is conditioned by an electronic circuit such that it modulates a DC signal in a system current control loop to provide continuous remote monitoring and alarm functions. Remote power is supplied to the sensor and conversion circuits through the current loop. The sensor detects changes in the charging current through the insulation ground conductor, indicating the degradation of the dielectric properties between the foil layers. The sensor and associated electronic circuitry are enclosed in a housing adaptable to be used with a capacitance tap common to high voltage measurement and control apparatus.

Abstract: A programmable data link module (32) for use in a time division multiplexing control system (30) having a plurality of modules interconnected by a bus (40) for passing control signals between data link modules on a serial multiplex basis. Each module includes an integrated circuit (80) having signal conditioning circuits (180, 186 and 188) including a programmable hysteresis circuit (126), a power on reset delay circuit (190), a safety input inhibit circuit (220), a clock loss detect circuit (240), a safety output protection circuit (262), a data verifier (260), a polarity selector for a third output terminal (350), an input synchronizer (182 and 184), a combined mode/sync output terminal (110), a multiplex clock output terminal (108), a programing circuit (232) for accepting programming over the clock bus (44) and data bus (46), input/output word extender circuits (104, 106), a high voltage protection circuit (420) including a transistor (600) and a data bus integrity checker (630).

Abstract: A system for modifying a printed circuit board allows parallel design of the printed circuit board and a programmable gate or logic array used on the circuit board. The printed circuit board design can be fixed before the gate array design is complete, which allows for flexibility in pin assignments of the high density integrated circuit mounted on the circuit board. Each pin of the gate array that can vary has a pair of vias connected by a conductive track. Changing signal paths requires cutting this track and using a jumper to make the new connection.

Abstract: A single phase, dry type transformer has an iron core, high voltage windings embedded in cast resin, and low voltage windings resin encapsulated. The low voltage winding is constructed with flexible sheet conductors. Insulating material includes a means to secure the windings in place during a vacuum and pressure resin impregnation process. The result is a coil that exhibits high short circuit protection due to the tightly bond conductors comparable to completely resin encased molded transformers at a substantially reduced cost.

Abstract: A coil assembly for use in an inductive apparatus, is comprised of a conductive material, either copper or aluminum, continuously wound around a circular or rectangular shape. At a predetermined number of turns, a terminal or tap is formed in the conductor. The tap is essentially a bump in the conductor that will protrude from the coil and be accessible to make connections to it after the coil assembly is complete. The insulation of the conductor is removed from the outside edge of the bump to form a point of contact. A C-clamp, formed from spring steel or other conductive material, functions to secure an external conductor having a lug attached to an end of conductor to the formed terminal. A bolt through the lug is secured by a tapered depression in the C-clamp that functions as a nut. The C-clamp includes an extension that provides additional pressure between the point of contact and the lug to make an electrical contact with a portion of the formed tap and the lug.

Abstract: A user interface for a control structure comprising a controller, and physical devices coupled to the controller is disclosed. The controller is adapted to control and monitor the physical devices. The user interface is coupled to the controller for displaying representations of status conditions of the physical device.

Abstract: A dry type transformer has an iron core, high voltage windings embedded in cast resin, and low voltage windings resin encapsulated. The low voltage winding is constructed with flexible sheet conductors coincident with layer insulation sheets that extend beyond the edge of the sheet conductor. Cooling air ducts are fabricated in the low voltage windings as it is wound. To prevent the extension of the layer insulation sheets from collapsing over the formed air ducts during a vacuum and pressure resin impregnation process, reinforcing means are added to the extensions to prevent them from collapsing.

Abstract: The present invention locates the primary winding of a transformer in a configuration where it substantially surrounds the secondary winding of the transformer in order to enhance the efficiency of the electromagnetic coupling. High magnetic permeability material surrounds portions of the primary winding of the transformer. The transformer is designed to efficiently operate at frequencies of approximately 50 kilohertz. In one preferred embodiment, the primary winding of the invention is formed of two U-shapes in which the parallel members of the U are substantially longer than the bottom portion of the U. The two U-shapes form a rectangular shape and the substantially parallel rectangular portions are surrounded by high magnetic permeability material to further enhance the electromagnetic coupling between the primary coil winding and the secondary coil winding. In another embodiment, the primary winding of the invention may be rectangular in shape.

Abstract: A non-ferrous current sensor is used to continuously measure the charging current magnitude in step-graded foil and paper insulation systems and capacitive insulation systems used on high voltage measurement and control apparatus such as instrument transformers and on the condenser bushings of power transformers and circuit breakers. The low voltage measured signal is conditioned by an electronic circuit such that it modulates a DC signal in a system current control loop to provide continuous remote monitoring and alarm functions. Remote power is supplied to the sensor and conversion circuits through the current loop. The sensor detects changes in the charging current through the insulation ground conductor, indicating the degradation of the dielectric properties between the foil layers. The sensor and associated electronic circuitry are enclosed in a housing adaptable to be used with a capacitance tap common to high voltage measurement and control apparatus.

Abstract: A programmable data link module (32) for use in a time division multiplexing control system (30) having a plurality of modules interconnected by a bus (40) for passing control signals between data link modules on a serial multiplex basis. Each module includes an integrated circuit (80) having signal conditioning circuits (180, 186 and 188) including a programmable hysteresis circuit (126), a power on reset delay circuit (190), a safety input inhibit circuit (220), a clock loss detect circuit (240), a safety output protection circuit (262), a data verifier (260), a polarity selector for a third output terminal (350), an input synchronizer (182 and 184), a combined mode/sync output terminal (110), a multiplex clock output terminal (108), a programming circuit (232) for accepting programming over the clock bus (44) and data bus (46), input/output word extender circuits (104, 106), a high voltage protection circuit (420) including a transistor (600) and a data bus integrity checker (630).

Abstract: A ground fault detection circuit monitors an interlock control circuit for use with a machine or process control system. The interlock control system utilizes electromechanical relays with hard contacts. The interlock control system will disable operation of the machine or process if any ground fault condition exists in the interlock control circuit. A ground condition in the machine or process control circuits is permissible. The system uses a redundant circuit path to verify the integrity of the components in the interlock control system. The control system includes an ungrounded isolation transformer for supplying power to separate monitoring relays interposed between each leg of the transformer and ground. The contacts of these relays are series connected with emergency-stop (e-stop) switches to energize interposing control relays. The outputs of the interposing relays are used to energize the final control relay that controls the operation of the machine or process.

Abstract: The present invention locates the primary winding of a transformer in a configuration where it substantially surrounds the secondary winding of the transformer in order to enhance the efficiency of the electromagnetic coupling. High magnetic permeability material surrounds portions of the primary winding of the transformer. The transformer is designed to efficiently operate at frequencies of approximately 50 kilohertz. In one preferred embodiment, the primary winding of the invention is formed of two U-shapes in which the parallel members of the U are substantially longer than the bottom portion of the U. The two U-shapes form a rectangular shape and the substantially parallel rectangular portions are surrounded by high magnetic permeability material to further enhance the electromagnetic coupling between the primary coil winding and the secondary coil winding. In another embodiment, the primary winding of the invention may be rectangular in shape.