Automatic Auxiliary Voltage Control for Engine-Driven Welders
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Solution Overview
Problem
Existing self-contained welding power supplies require repeated adjustments of the excitation controller when switching between welding and auxiliary power operations, leading to inconvenience and potential improper welding due to the need for full excitation during auxiliary power use.
Innovation Solution
A system that automatically sets the permissible power setting on auxiliary power outputs of an engine-driven welder, allowing for seamless transition from welding to auxiliary power operations by using a relay to adjust the field voltage input signal based on thresholds or welding status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the excitation controller is set to less than 100% during welding operations, then welding power efficiency is improved, but auxiliary power voltage becomes insufficient when welding ceases
Solution Approach 1:
The excitation controller dynamically adjusts the field excitation level based on the operational state of the welder. When welding operations are detected, the controller reduces excitation to less than 100% to improve welding power efficiency. When welding ceases and auxiliary power is required, the controller automatically increases excitation back to 100% to ensure sufficient voltage for auxiliary devices. This dynamic adjustment resolves the contradiction by allowing the system to optimize for different operational modes.
Solution Approach 2:
The system changes the excitation parameter (field voltage) based on operational conditions. During welding, the excitation parameter is reduced to improve power efficiency. When switching to auxiliary power mode, the excitation parameter is increased to ensure adequate voltage output. This parameter change strategy allows the generator to efficiently serve both welding and auxiliary power needs without manual intervention.
2Power
If the excitation controller is manually adjusted when switching between welding and auxiliary power, then power output is optimized, but operational convenience deteriorates due to repeated adjustments
Solution Approach 1:
The excitation controller is designed to automatically detect when welding operations cease and autonomously adjust the field excitation to 100% to restore full voltage for auxiliary power. This self-service capability eliminates the need for manual intervention, allowing the system to optimize power output while maintaining ease of operation. The controller monitors system conditions and performs necessary adjustments without user input.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the operational state of the welder and automatically adjust excitation accordingly. When welding operations are detected, the feedback signal triggers reduced excitation for welding optimization. When welding ceases, the feedback signal triggers increased excitation for auxiliary power readiness. This closed-loop feedback system maintains power optimization while eliminating manual adjustment requirements.
3Reliability
If full excitation is maintained for auxiliary power readiness, then auxiliary power voltage is sufficient, but welding power efficiency decreases
Solution Approach 1:
The excitation controller dynamically adapts the field excitation level based on real-time detection of operational mode. During welding operations, excitation is reduced to less than 100% to optimize welding power efficiency. When welding ceases and auxiliary power is needed, excitation automatically returns to 100% to ensure full voltage availability. This dynamic behavior allows the system to maintain reliability for auxiliary power while improving welding efficiency when active.
Solution Approach 2:
The system changes the excitation parameter based on operational requirements. When welding is active, the excitation parameter is optimized for welding efficiency. When welding stops and auxiliary power is required, the excitation parameter is changed to 100% to ensure adequate voltage for auxiliary devices. This parameter adaptation resolves the contradiction by matching excitation levels to actual operational needs.
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
Eliminates the need for manual adjustments, ensuring consistent voltage for auxiliary devices and preventing errors during power transitions, thereby enhancing operational efficiency and reducing the risk of improper welding.
Implementation Method 1
the excitation controller will also affect the voltage at the auxiliary power receptacles
Data Source
AI summary
A self-contained welding power supply capable of, upon termination of welding operation, automatically setting a control signal for auxiliary power is provided. The power supply comprises an engine, a generator driven by the engine, and an excitation system that controls power output of the generator. The excitation system includes an output controller and a DC controller. The output controller includes circuitry that generates a field voltage control signal to be sent to the DC controller to regulate DC power going to field windings of the generator. Upon termination of the welding operation, the field voltage control signal is automatically set to a value appropriate for the auxiliary system operation.