Abstract: Disclosed is a system for interdependent control of multiple power sources. The system includes at least first and second power sources for supplying power to an electrical load. At least first and second sensors are respectively coupled with outputs of the first and second power sources, such that the first and second sensors respectively emit first and second signals indicative of the output of the first and second power sources. A comparator unit is coupled to the first and second sensors for comparing the first and second signals emitted by the first and second sensors. The comparator unit is configured for emitting a difference signal indicating a difference between the first and second signals. A controller unit coupled to the comparator unit and at least one of said first and second power sources is configured for controlling at least one of said first and second power sources based on the difference signal.

Abstract: The systems and methods of the present invention provide a circuit for controlling the magnitude of the main and pilot arc current provided to an arc cutting or welding machine. In one embodiment, the circuit allows the user to set the pilot arc current such that it automatically tracks the main arc current setting. The pilot arc current is set to a value that is proportional to the main arc current, such that the pilot arc current value is tailored to the specific cutting operation to be performed and/or the specific nozzle and electrode being used. In an alternative embodiment, the circuit allows the user to select from different pilot arc current levels, such as low, medium, and high current levels. This allows the user to override the pilot arc control in instances where the plasma arc cutting or welding machine is operated under conditions not optimal for the selected nozzle and electrode.

Abstract: The cutting or welding system includes a power source having, in one embodiment, a stabilization circuit for reducing arc rectification and, in another embodiment, a number of firing circuits for controlling the flow of current through a rectifier in order to more precisely provide a rectified alternating current. The power source also includes a rectifier having a number of current control devices for providing rectified current having alternating positive and negative cycles across the arc gap. Accordingly, the electrode alternates between an electrode negative state and an electrode positive state, respectively.

Abstract: A power source apparatus for supplying electrical power for an arc welder includes a frame having a base member and first and second pairs of support members each defining an inverted V-shaped configuration mounted to the opposite side edges of the base member. An inverted channel cross member extends transversely between the upper ends of the support members. The support members each define a U-shaped channel having a pair of sidewalls and a connecting wall therebetween and are oriented such that the connecting walls face away from each other. An associated assembly method includes the steps of adjoining the ends of first and second pairs of support members and connecting them with a cross member to define a frame subassembly. At least a portion of the power circuit of the arc welder power source is then mounted on the frame subassembly before it is attached to the power source frame. A busbar assembly for supporting two rows of capacitors in parallel on the frame of an arc welder is also provided.

Abstract: A welding power system is described wherein a programmable controller and a conventional power supply are coupled by a circuit which simulates a control potentiometer. The coupling circuit provides an adjustable output signal intermediate between high and low potentials depending upon the level of an input control signal. The coupling circuit converts the input control signal into a pulse width modulated signal, multiplexes the high and low potentials in accordance with the pulse width modulated signal, and time-averages the multiplexed signal to provide an output control signal. An optical isolator is preferably included for direct current isolation of the input and output signals.