Battery-Powered Flash-Butt Rail Welding With Pulsed Power Conversion

The patent implements periodic action by using a pulsed frequency converter that delivers high-power welding current only during the actual welding operation rather than continuously running a diesel generator. The system uses a DC battery system that can be charged during non-welding periods and delivers concentrated power during welding, eliminating continuous fuel consumption while maintaining sufficient power availability when needed.

The patent replaces the mechanical diesel-powered AC generator system with an electrical DC battery system combined with a pulsed frequency converter. This substitution eliminates the need for continuous fuel combustion and mechanical engine operation, reducing fuel consumption and environmental harm while providing sufficient power for welding through controlled electrical pulses.

The patent replaces the diesel-powered AC generator with a DC battery system and pulsed frequency converter, eliminating the combustion engine that produces harmful emissions. The electrical system provides sufficient power for welding without generating exhaust gases or other environmental pollutants, directly addressing the emissions problem while maintaining power availability.

The patent converts the harmful continuous operation of diesel generators into beneficial concentrated electrical pulses. By using a DC battery system that can be charged from various sources (including regenerative braking or solar panels during non-welding periods), the system transforms what would have been continuous fuel consumption and emissions into clean, on-demand electrical power delivery that benefits both welding quality and environmental protection.

The patent uses a pulsed frequency converter as an intermediary device that bridges the DC battery system and the welding operation. This intermediary component manages the complex task of converting DC power into controlled pulsed welding current, protecting the battery system from direct exposure to welding loads while enabling precise power delivery. The intermediary simplifies the overall system architecture by centralizing the conversion function in a single dedicated component.

The DC battery system serves multiple functions: it stores energy for welding operations, provides power during welding, and can be recharged from various sources during non-welding periods. The pulsed frequency converter also serves dual purposes by both converting DC to pulsed welding current and protecting the battery system from electrical surges. This multi-functionality reduces the need for separate dedicated components, thereby managing system complexity.

The patent applies preliminary action by charging the DC battery system during non-welding periods and before welding operations begin. The battery is pre-charged from various sources including regenerative braking during train operations, solar panels during daytime, or external power sources at maintenance facilities. This preliminary charging ensures sufficient energy is stored before welding operations, enabling reduced fuel consumption during actual welding while maintaining adequate operational duration.

The patent ensures continuity of useful action by implementing multiple charging opportunities for the DC battery system throughout the day. Rather than requiring a single large battery, the system can be incrementally recharged during various periods (regenerative braking, solar exposure, overnight), maintaining continuous readiness for welding operations. This approach extends the effective operational duration by allowing the battery to be replenished multiple times without requiring continuous diesel generator operation.