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An engine welder having a single rotor and a single stator, and methods of distributing electrical power capacity of the engine welder to various welding windings and auxiliary windings of the engine welder. The single rotor is driven at saturation current and independent control of the welding outp

An engine welder having a single rotor and a single stator, and methods of distributing electrical power capacity of the engine welder to various welding windings and auxiliary windings of the engine welder. The single rotor is driven at saturation current and independent control of the welding outputs is accomplished on the stator side of the engine welder. Means for supplying the full electrical power capacity of the engine welder to a single stator welding winding are provided. Furthermore, means for distributing the electrical power capacity of the engine welder between welding windings and/or auxiliary windings of the single stator are provided.

대표청구항 ▼

1. An engine welder capable of supplying up to a full electrical power capacity, said engine welder comprising: an engine capable of providing rotating mechanical drive power;a single rotor having at least one field winding wound on a stack of iron laminations configured to be electrically driven at

1. An engine welder capable of supplying up to a full electrical power capacity, said engine welder comprising: an engine capable of providing rotating mechanical drive power;a single rotor having at least one field winding wound on a stack of iron laminations configured to be electrically driven at a saturation current which fully saturates a generator magnetics of the engine welder;a rotatable drive shaft operatively connecting said rotor to said engine; anda single stator surrounding said single rotor and having a first stator welding winding, at least a second stator welding winding, and at least a first stator auxiliary winding, wherein said engine, said single rotor, and said single stator are configured to supply said full electrical power capacity to said first stator welding winding as said rotor is driven at said saturation current. 2. The engine welder of claim 1 wherein said engine, said single rotor, and said single stator are further capable of supplying less than said full electrical power capacity to said at least a second stator welding winding. 3. The engine welder of claim 1 wherein said engine, said single rotor, and said single stator are further capable of supplying at least a portion of said full electrical power capacity to said at least a first stator auxiliary winding. 4. The engine welder of claim 1 further comprising a first rectifier circuit operatively connected to an output of said first stator welding winding and at least a second rectifier circuit operatively connected to an output of said at least a second stator welding winding. 5. The engine welder of claim 1 wherein said at least a first stator auxiliary winding provides a single phase auxiliary power. 6. The engine welder of claim 1 wherein said at least a first stator auxiliary winding provides a three phase auxiliary power. 7. The engine welder of claim 4 further comprising a first output control circuit operatively connected to an output of said first rectifier circuit and capable of controlling a first welding output current over a full range of welding output current levels up to said full electrical power capacity of said engine welder. 8. The engine welder of claim 7 further comprising at least a second output control circuit operatively connected to an output of said at least a second rectifier circuit and capable of controlling a second welding output current over a full range of welding output current levels, independently of said first welding output current, up to less than said full electrical power capacity of said engine welder. 9. The engine welder of claim 8 wherein said first output control circuit includes at least one chopper circuit, and said at least a second output control circuit comprises at least one chopper circuit. 10. The engine welder of claim 8 wherein said first output control circuit includes at least one inverter circuit, and said at least a second output control circuit includes at least one inverter circuit. 11. The engine welder of claim 7 wherein said first output control circuit is capable of controlling said first welding output current at a control rate of greater than 18 KHz over said full range of welding output current levels. 12. The engine welder of claim 8 wherein said at least a second output control circuit is capable of controlling said second welding output current at a control rate of greater than 18 KHz over said full range of welding output current levels. 13. An engine welder capable of supplying up to a maximum electrical power capacity, said engine welder comprising: first welding output means;at least second welding output means;at least first auxiliary power output means; andmeans for supplying said maximum electrical power capacity to said first welding output means via a first stator welding winding and via a single rotor of the engine welder having at least one field winding wound on a stack of iron laminations configured to be driven at a saturation current to fully saturate a generator magnetics of the engine welder. 14. The engine welder of claim 13 further comprising means for supplying less than said maximum electrical power capacity to said at least second welding output means. 15. The engine welder of claim 13 further comprising means for simultaneously supplying a first portion of said maximum electrical power capacity to said first welding output means and a second portion of said maximum electrical power capacity to said at least a second welding output means, where the sum of said first portion and said second portion are less than or equal to said maximum electrical power capacity. 16. The engine welder of claim 13 further comprising means for simultaneously supplying a first portion of said maximum electrical power capacity to said first welding output means and a second portion of said maximum electrical power capacity to said at least a first auxiliary power output means, where the sum of said first portion and said second portion are less than or equal to said maximum electrical power capacity. 17. The engine welder of claim 13 further comprising means for simultaneously supplying a first portion of said maximum electrical power capacity to said first welding output means, a second portion of said maximum electrical power capacity to said at least a second welding output means, and a third portion of said maximum electrical power capacity to said at least a first auxiliary power output means, where the sum of said first portion, said second portion, and said third portion are less than or equal to said maximum electrical power capacity. 18. The engine welder of claim 13 further comprising means for controlling an output current of said first welding output means over a full range of output current levels up to said maximum electrical power capacity. 19. The engine welder of claim 13 further comprising means for controlling an output current of said at least a second welding output means over a full range of output current levels up to less than said maximum electrical power capacity. 20. The engine welder of claim 13 wherein said at least a first auxiliary power output means provides a single phase auxiliary power. 21. The engine welder of claim 13 wherein said at least a first auxiliary power output means provides a three phase auxiliary power. 22. A method of supplying a maximum electrical power capacity with an engine welder having a single rotor capable of rotating within a single stator, said method comprising: driving at least one field winding wound on a stack of iron laminations of said single rotor at a saturation current to fully saturate a generator magnetics of the engine welder;inducing a first welding current in a first stator welding winding, wound on said single stator of said engine welder, supplying said maximum electrical power capacity to said first stator welding winding;inducing at least a first auxiliary current in at least a first stator auxiliary winding, wound on said single stator of said engine welder, supplying less than or equal to said maximum electrical power capacity to said at least a first stator auxiliary winding; andinducing at least a second welding current in at least a second stator welding winding, wound on said single stator of said engine welder, supplying less than said maximum electrical power capacity to said at least a second stator welding winding. 23. The method of claim 22 further comprising inducing said first welding current in said first stator welding winding supplying a first portion of said maximum electrical power capacity while simultaneously inducing said at least a second welding current in said at least said second stator welding winding supplying a second portion of said maximum electrical power capacity, where a sum of said first portion and said second portion are less than or equal to said maximum electrical power capacity. 24. The method of claim 22 further comprising inducing said first welding current in said first stator welding winding supplying a first portion of said maximum electrical power capacity while simultaneously inducing said at least a first auxiliary current in said at least a first stator auxiliary winding supplying a second portion of said maximum electrical power capacity, where a sum of said first portion and said second portion are less than or equal to said maximum electrical power capacity. 25. The method of claim 22 further comprising inducing said first welding current in said first stator welding winding supplying a first portion of said maximum electrical power capacity, while simultaneously inducing said at least a second welding current in said at least said second stator welding winding supplying a second portion of said maximum electrical power capacity, while simultaneously inducing said at least a first auxiliary current in said at least a first stator auxiliary winding supplying a third portion of said maximum electrical power capacity, where a sum of said first portion, said second portion, and said third portion are less than or equal to said maximum electrical power capacity. 26. The method of claim 22 further comprising controlling a first welding output current, derived from said first welding current, over a full range of welding output current levels up to said maximum electrical power capacity while said single rotor of said engine welder is driven at said saturation current. 27. The method of claim 22 further comprising controlling a first welding output current, derived from said first welding current, over a full range of welding output current levels up to less than said maximum electrical power capacity while said single rotor of said engine welder is driven at said saturation current. 28. The method of claim 27 further comprising controlling at least a second welding output current, derived from said at least a second welding current, over a full range of welding output current levels up to less than said maximum electrical power capacity while said single rotor of said engine welder is driven at said saturation current.