Hybrid Welding Power Supply for Battery-Aware Output Control
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Solution Overview
Problem
Conventional welding power supplies are limited by their rated output, and battery-assisted systems require reconfiguration between charging and welding, leading to operator-dependent decision-making and inefficiencies in energy management.
Innovation Solution
Hybrid welding systems with control circuitry and monitoring capabilities that determine utility power capability and battery condition, providing operator guidance on improved welding parameters and operations by integrating power conversion circuitry, bidirectional DC-DC converters, and user interfaces to manage energy sources effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery-assisted systems are used to increase welding capacity, then the rated output of welding power supplies is improved, but the system complexity and operational efficiency deteriorate due to required reconfiguration between charging and welding modes
Solution Approach 1:
The patent combines the welding power supply and battery system into a single integrated hybrid welding system. The power conversion circuitry simultaneously handles both utility power conversion and battery charging/discharging operations, eliminating the need for separate charging and welding modes. The control circuitry manages multiple operations (charging, welding, monitoring) within a unified system architecture, resolving the contradiction by merging previously separate functions into one cohesive system.
Solution Approach 2:
The power conversion circuitry is designed to perform multiple functions: converting utility power to charge batteries, converting battery power for welding operations, and providing real-time monitoring of system state. The bidirectional DC-DC converter can operate in multiple modes (charging mode, welding mode, standby mode) without requiring physical reconfiguration. This multi-functionality allows the system to adapt to different operational requirements while maintaining a single integrated configuration.
2Ease of operation
If conventional battery-assisted systems require reconfiguration between charging and welding, then operator decision-making is simplified, but productivity and operational efficiency deteriorate due to manual intervention requirements
Solution Approach 1:
The hybrid welding system incorporates intelligent control circuitry that automatically monitors system state (battery charge level, utility power availability, welding parameters) and makes operational decisions without operator intervention. The control circuitry autonomously determines when to charge batteries, when to use battery power for welding, and how to manage power conversion operations. This self-service capability maintains ease of operation while dramatically improving productivity by eliminating manual reconfiguration steps and enabling continuous operation.
Solution Approach 2:
The system implements real-time feedback through monitoring circuitry that continuously tracks battery state of charge, utility power status, and welding load requirements. This feedback information is processed by the control circuitry to dynamically adjust operational parameters and automatically transition between charging and welding modes. The feedback mechanism enables the system to respond to changing conditions in real-time, maintaining optimal efficiency without requiring operator awareness or intervention.
3Use of energy by moving object
If hybrid welding systems integrate power conversion circuitry and bidirectional DC-DC converters, then energy management capability is improved, but device complexity increases
Solution Approach 1:
The power conversion system is segmented into distinct functional modules: utility power input stage, bidirectional DC-DC converter stage, and battery interface stage. Each module performs a specific function and can be independently controlled. The bidirectional DC-DC converter is further segmented into controlled operating modes (charging direction, discharging direction, standby). This segmentation allows complex energy management functions to be implemented through coordinated operation of simpler, well-defined modules, managing complexity through functional decomposition.
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
Enhances usability and productivity by providing real-time energy management, reducing unexpected outages and ensuring proper equipment matching with available energy, thus optimizing welding operations.
Implementation Method 1
power conversion circuitry and bidirectional DC-DC converters
Data Source
AI summary
Disclosed example welding systems comprise: a power input configured to receive input power from batteries; power conversion circuitry configured to convert the input power from the batteries to welding power; a user interface configured to input one or more parameters for the welding power; a battery monitor configured to determine properties of the batteries; and control circuitry configured to: determine a welding capacity associated with the parameters for the welding power and based on the determined properties of the batteries; in response to determining that the welding capacity does not support the parameters for the welding power, output an indication representative of limitations on the parameters for the welding power based on the welding capacity; in response to determining that the welding capacity supports the parameters for the welding power, output an indication of remaining welding capacity; and control the power conversion circuitry based on the parameters.