Abstract: A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

Abstract: A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

Abstract: A method and apparatus for providing engine driven welding-type power supply includes an engine, a generator, an input power circuit, a welding-type power circuit, an auxiliary power circuit and a controller. The generator includes permanent magnets that create and provides a generator output from at least one polyphase winding. The input power circuit is connected to the generator output and the welding-type power circuit is connected to the input circuit, and provides a welding-type output. The auxiliary power circuit is connected to the input circuit and provides an auxiliary power output. The controller is connected to the auxiliary power and the welding type power circuits, and can command that there be no load for the generator. The generator is connected to the engine and connected to function as a flywheel to the engine and the engine does not include a flywheel other than the generator.

Abstract: A method and apparatus for providing engine driven welding-type power supply includes an engine, a generator, an input power circuit, a welding-type power circuit, an auxiliary power circuit and a controller. The generator includes permanent magnets that create and provides a generator output from at least one polyphase winding. The input power circuit is connected to the generator output and the welding-type power circuit is connected to the input circuit, and provides a welding-type output. The auxiliary power circuit is connected to the input circuit and provides an auxiliary power output. The controller is connected to the auxiliary power and the welding type power circuits, and can command that there be no load for the generator. The generator is connected to the engine and connected to function as a flywheel to the engine and the engine does not include a flywheel other than the generator.

Abstract: A method and apparatus for providing engine driven welding-type power supply includes an engine, a generator, an input power circuit, a welding-type power circuit, an auxiliary power circuit and a controller. The generator includes permanent magnets that create and provides a generator output from at least one polyphase winding. The input power circuit is connected to the generator output and the welding-type power circuit is connected to the input circuit, and provides a welding-type output. The auxiliary power circuit is connected to the input circuit and provides an auxiliary power output. The controller is connected to the auxiliary power and the welding type power circuits, and can command that there be no load for the generator. The generator is connected to the engine and connected to function as a flywheel to the engine and the engine does not include a flywheel other than the generator.

Abstract: A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

Abstract: A power supply includes an electrical component having at least one pin extending a first distance from a body portion of the electrical component to a circuit board. The power supply also includes a heat sink coupled to the body portion of the electrical component and extending substantially parallel to the at least one pin for approximately the first distance from the body portion to the circuit board. In one embodiment, the at least one pin of the electrical component is not trimmed during assembly of the power supply. In another embodiment, the power supply includes a heat sink hanging over an edge of the circuit board. Moreover, in certain embodiments, a transformer lead is coupled to a diode using a fastener.

Abstract: A welding power supply includes a housing and a one-piece chassis. The one-piece chassis is coupled to the housing and configured to be enclosed within the housing. Moreover, the one-piece chassis is configured to be selectively removable from the housing and the one-piece chassis is configured to have multiple components coupled thereto. The components include one or more transformers, a fan blade, one or more rectifiers, one or more inductors, and control circuitry.

Abstract: A power supply includes an electrical component having at least one pin extending a first distance from a body portion of the electrical component to a circuit board. The power supply also includes a heat sink coupled to the body portion of the electrical component and extending substantially parallel to the at least one pin for approximately the first distance from the body portion to the circuit board. In one embodiment, the at least one pin of the electrical component is not trimmed during assembly of the power supply. In another embodiment, the power supply includes a heat sink hanging over an edge of the circuit board. Moreover, in certain embodiments, a transformer lead is coupled to a diode using a fastener.

Abstract: A welding power supply includes a housing and a one-piece chassis. The one-piece chassis is coupled to the housing and configured to be enclosed within the housing. Moreover, the one-piece chassis is configured to be selectively removable from the housing and the one-piece chassis is configured to have multiple components coupled thereto. The components include one or more transformers, a fan blade, one or more rectifiers, one or more inductors, and control circuitry.

Abstract: The present invention is directed to a bobbin for an inductor assembly that is preferably molded of a plastic material incorporating a flange to maintain a uniform and constant gap or separation between a pair of ferrite E-cores. Preferably, the bobbin includes a number of hollow bosses designed to receive self-tapping screws so as to directly mount the bobbin to a mounting plate. Additionally, a pair of tempered brass spring clips is used to secure the cores to the bobbin. To reduce breakage of the bobbin, each clip engages the bobbin perpendicular to the width of the ferrite core.

Abstract: A snap-in heat sink assembly that has an injection molded one piece frame having a plurality of spring members extending outwardly with protrusions at the free ends thereof. The assembly has a spring located against the frame and an electronic component is located atop of the spring. A heat sink has lateral surfaces with elongated grooves formed along those lateral surfaces. The sink is affixed to the frame by a simple step of inserting the heat sink into the space between the spring members such that the protrusions of the spring members snap into the grooves when the heat sink is in the desired location. By sandwiching the spring between the frame and the electronic component, the spring creates a bias to force the electronic component against the heat sink to assure good conductivity of heat from the electronic component through the heat sink.

Abstract: A high frequency transformer for a welding-type device is provided. The transformer includes a pair of ferrite cores and a bobbin configured to receive and support the pair of ferrite cores. A primary winding assembly, as well as, a secondary winding assembly is provided. The secondary winding assembly is in parallel with a center topped tertiary winding assembly. The tertiary winding assembly includes a number of coil sections such that each coil section is wrapped around an outer leg of a ferrite core.

Abstract: A high frequency transformer for a welding-type device is provided. The transformer includes a pair of ferrite cores and a bobbin configured to receive and support the pair of ferrite cores. A primary winding assembly, as well as, a secondary winding assembly is provided. The secondary winding assembly is in parallel with a center topped tertiary winding assembly. The tertiary winding assembly includes a number of coil sections such that each coil section is wrapped around an outer leg of a ferrite core.

Abstract: The present invention is directed to a bobbin for an inductor assembly that is preferably molded of a plastic material incorporating a flange to maintain a uniform and constant gap or separation between a pair of ferrite E-cores. Preferably, the bobbin includes a number of hollow bosses designed to receive self-tapping screws so as to directly mount the bobbin to a mounting plate. Additionally, a pair of tempered brass spring clips is used to secure the cores to the bobbin. To reduce breakage of the bobbin, each clip engages the bobbin perpendicular to the width of the ferrite core.

Abstract: A snap-in heat sink assembly that has an injection molded one piece frame having a plurality of spring members extending outwardly with protrusions at the free ends thereof. The assembly has a spring located against the frame and an electronic component is located atop of the spring. A heat sink has lateral surfaces with elongated grooves formed along those lateral surfaces. The sink is affixed to the frame by a simple step of inserting the heat sink into the space between the spring members such that the protrusions of the spring members snap into the grooves when the heat sink is in the desired location. By sandwiching the spring between the frame and the electronic component, the spring creates a bias to force the electronic component against the heat sink to assure good conductivity of heat from the electronic component through the heat sink.

Abstract: A power supply connector includes a cable receptacle, a front bulkhead insulator and a rear bulkhead insulator. The bulkhead insulators are mounted on the cable receptacle and the power supply chassis. At least one O ring is disposed between the front and rear bulkhead insulators, to seal out water. The front bulkhead insulator includes a stepped portion that mates with a stepped portion on the rear bulkhead insulator. The front bulkhead insulator provides an elongated path from the chassis to the cable receptacle. Also, an O ring is disposed between the cable receptacle and the front bulkhead insulator, to seal out water.

Abstract: A power supply connector includes a cable receptacle, a front bulkhead insulator and a rear bulkhead insulator. The bulkhead insulators are mounted on the cable receptacle and the power supply chassis. At least one O ring is disposed between the front and rear bulkhead insulators, to seal out water. The front bulkhead insulator includes a stepped portion that mates with a stepped portion on the rear bulkhead insulator. The front bulkhead insulator provides an elongated path from the chassis to the cable receptacle. Also, an O ring is disposed between the cable receptacle and the front bulkhead insulator, to seal out water.

Abstract: A housing for a welding power supply, the housing including a main chamber and a tunnel through the main chamber, a number of electrical components mounted on the tunnel, a number of heat sinks mounted in the tunnel in operative engagement with said electrical components, a fan mounted in the tunnel for blowing air through said tunnel to cool the electrical components, an electrical control board and interconnect board mounted in the main chamber in a spaced relation to said tunnel to isolate the boards from the heat and air flow through the tunnel.