Systems and methods to mitigate audible noise in welding-type power supplies

Abstract

Apparatus, systems, and/or methods for mitigating audible noise generated by a welding-type power supply are disclosed. In some examples, the switching frequency of the welding-type power supply may be changed to a frequency that is outside the audible range for humans. This strategy takes advantage of the fact that the observed audible noise is generated by vibrating components within the welding-type power supply that vibrate at a frequency related to the switching frequency. Other noise mitigation strategies include dithering and deactivation of portions of the welding-type power supply that vibrate to generate the audible noise.

What is claimed is: 
     
         1 . A welding-type power supply, comprising:
 power conversion circuitry configured to convert input power to welding-type output power; and   control circuitry configured to control the power conversion circuitry using a control signal, the control signal having a signal frequency, and the control circuitry configured to set the signal frequency based on a load state, wherein the control circuitry is configured to set the signal frequency to a second frequency outside of an audible frequency range in response to the load state comprising a low load.   
     
     
         2 . The power supply of  claim 1 , wherein the load state comprises a high load or a low load. 
     
     
         3 . The power supply of  claim 1 , wherein the load state comprises a high load when the welding-type output power is used during a welding-type operation and the low load when the welding-type output power is not used during a welding-type operation. 
     
     
         4 . The power supply of  claim 3 , wherein the control circuitry is configured to set the signal frequency to a first frequency in response to the load state comprising the high load, and to the second frequency in response to the load state comprising the low load. 
     
     
         5 . The power supply of  claim 4 , wherein the first frequency is within the audible frequency range. 
     
     
         6 . The power supply of  claim 4 , wherein the second frequency is higher than the first frequency. 
     
     
         7 . The power supply of  claim 4 , wherein the first frequency is between approximately 7 kHz and 15 kHz, and the second frequency is not between approximately 7 kHz and 15 kHz. 
     
     
         8 . The power supply of  claim 1 , wherein the power conversion circuitry comprises a stacked boost converter having a controllable circuit element, the controllable circuit element configured to switch between a first state and a second state based on the control signal. 
     
     
         9 . A welding-type system, comprising:
 a welding-type instrument configured to use welding-type output power during a welding-type operation; and   a welding-type power supply, comprising:
 power conversion circuitry configured to convert input power to the welding-type output power; and 
 control circuitry configured to control the power conversion circuitry using a control signal, the control signal having a signal frequency, and the control circuitry configured to set the signal frequency based on a load state, wherein the control circuitry is configured to set the signal frequency to a second frequency outside of an audible frequency range in response to the load state comprising a low load. 
   
     
     
         10 . The welding system of  claim 9 , wherein the load state comprises a high load when the welding-type instrument is conducting the welding-type operation and the low load when the welding-type instrument is not conducting the welding-type operation. 
     
     
         11 . The welding system of  claim 10 , wherein the control circuitry is configured to set the signal frequency to a first frequency in response to the load state comprising the high load, and to the second frequency in response to the load state comprising the low load. 
     
     
         12 . The welding system of  claim 11 , wherein the second frequency is zero. 
     
     
         13 . The welding system of  claim 11 , wherein the control circuitry is further configured to set the signal frequency to a third frequency in response to the load state comprising the low load. 
     
     
         14 . The welding system of  claim 11 , wherein the first frequency is between approximately 7 kHz and 15 kHz, and the second frequency is not between approximately 7 kHz and 15 kHz. 
     
     
         15 . A method for controlling a welding-type power supply, comprising:
 determining a load state of a welding-type power supply;   setting a non-zero signal frequency of a control signal based on the load state, wherein the signal frequency is set to a second frequency outside of an audible frequency range in response to the load state comprising a low load; and   controlling power conversion circuitry of the welding-type power supply using the control signal.   
     
     
         16 . The method of  claim 15 , wherein determining the load state comprises determining whether an inverter of the power conversion circuitry is active. 
     
     
         17 . The method of  claim 16 , wherein determining whether the inverter is active comprises determining whether a welding-type operation is active. 
     
     
         18 . The method of  claim 17 , wherein the load state comprises a high load when the welding-type operation or the inverter is active and the low load when the welding-type operation or the inverter is inactive. 
     
     
         19 . The method of  claim 15 , wherein determining the load state comprises predicting a future load state based on sensor input. 
     
     
         20 . The method of  claim 15 , wherein setting the signal frequency comprises setting the signal frequency to a first frequency when the load state is a high load and setting the signal frequency to the second frequency when the load state is the low load, the second frequency being higher than the first frequency.