Auxiliary Power Module for Welding Systems
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Solution Overview
Problem
Welding-type systems often lack auxiliary power capabilities, particularly in environments where utility power like 120 vac is not available, and users may need additional power for tools or components like coolers, necessitating a flexible and field-installable power solution.
Innovation Solution
A welding-type power supply with an auxiliary power module that can be field-installed, providing isolated auxiliary power through a standard power receptacle and wiring harnesses, allowing for easy connection and disconnection without tools, and featuring a dual, stacked two-switch forward converter topology for efficient power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If auxiliary power supply is added to welding-type system, then auxiliary power capability is improved, but device complexity increases
Solution Approach 1:
The auxiliary power supply is implemented as a separate, modular module that can be independently installed and removed. This segmentation allows the auxiliary power capability to be added without redesigning the entire welding system, thus improving adaptability while minimizing the increase in overall system complexity.
Solution Approach 2:
The auxiliary power module is designed to provide multiple functions: it supplies power to auxiliary devices, provides isolation for safety, and can be installed in various welding system configurations. This multi-functionality justifies the added complexity by delivering multiple benefits from a single module.
2Ease of operation
If auxiliary power module is field-installed, then ease of installation is improved, but reliability may worsen due to additional connection points
Solution Approach 1:
The modular design with standardized connection interfaces allows field installation without requiring complex integration work. The segmented architecture with defined connection points simplifies the installation process while maintaining reliability through standardized, tested connection protocols.
Solution Approach 2:
The auxiliary power module acts as an intermediary component with standardized interfaces that mediate between the welding system's power circuit and external auxiliary devices. This intermediary role allows for reliable, standardized connections that can be easily installed in the field while maintaining system integrity.
3Object-affected harmful factors
If electrical isolation is provided between auxiliary power and welding power circuits, then safety is improved, but device complexity increases
Solution Approach 1:
The auxiliary power module serves as an isolated intermediary that provides electrical separation between the welding power circuit and auxiliary power outputs. This intermediary approach delivers the necessary safety isolation while keeping the circuit design manageable through modular architecture.
Solution Approach 2:
The electrical isolation is achieved through segmented circuit architecture where the auxiliary power module is electrically separated from the main welding power circuit. This segmentation provides safety isolation while allowing each segment to be designed and tested independently, reducing overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the provision of reliable auxiliary power for welding systems, decoupling control and auxiliary power loads, and allowing users to install necessary power components in the field, enhancing operational flexibility and safety.
Implementation Method 1
dual, stacked two-switch forward converter topology for efficient power conversion
Data Source
AI summary
A method and apparatus for providing a welding-type power includes a housing with an auxiliary power mount, and a welding type power circuit. A controller, a control power circuit, and an auxiliary power module are disposed in the housing. The auxiliary power module/circuit is mounted to the auxiliary power mount. A standard power receptacle is connected to the auxiliary power module. At least one wiring harness connects the welding type power circuit to the auxiliary power module/circuit, which is the only electrical connection between the auxiliary power circuit and the welding type power circuit. The auxiliary power is electrically isolated from the input power and the welding type power.