Multi-Channel Battery Stud Welder for Portable High-Current Welding
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Solution Overview
Problem
Conventional engine-generator stud welding systems are large, difficult to maneuver, extremely loud, and not fuel efficient, limiting their portability and operational flexibility.
Innovation Solution
A battery-powered stud welding system that includes a battery pack with multiple Lithium Ion battery cells, an input module for charging, an output module for supplying welding current, and a controller for managing the power distribution to a stud weld gun, enabling portable and efficient welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an engine-generator system is used for stud welding, then sufficient power for welding can be provided, but the system becomes large, difficult to maneuver, loud, and fuel inefficient
Solution Approach 1:
The battery pack is divided into multiple independent battery channels (first battery channel, second battery channel, third battery channel, fourth battery channel), each with its own switches and control circuitry. This segmentation allows flexible configuration and independent management of power delivery, enabling portable operation while maintaining sufficient welding power through selective activation of channels.
Solution Approach 2:
The system changes the power delivery parameters by using multiple battery channels with configurable current output (e.g., 500 amps per channel). By adjusting which channels are active and their individual current contributions, the system can deliver variable total current (e.g., 2000-3000 amps) suitable for welding while maintaining a compact, portable battery pack design.
2Power
If an engine-generator system is used for stud welding, then sufficient power for welding can be provided, but the system becomes extremely loud
Solution Approach 1:
The patent replaces the mechanical engine-generator system with an electrical battery-based power system. This substitution eliminates the combustion engine and its associated noise, providing a quiet operating environment while still delivering the necessary welding current through the battery channels and control circuitry.
3Power
If an engine-generator system is used for stud welding, then sufficient power for welding can be provided, but the system is not fuel efficient
Solution Approach 1:
The patent replaces the fuel-consuming engine-generator with an electric battery system. This substitution eliminates fuel consumption entirely, providing a clean energy source that charges batteries which then supply power for welding operations, dramatically improving energy efficiency and eliminating exhaust emissions.
4Ease of operation
If a battery pack with multiple channels is used, then portable and efficient welding operations are enabled, but the device complexity increases
Solution Approach 1:
The patent merges multiple battery channels into a unified power delivery system controlled by a single controller. The controller coordinates the switches of all battery channels (first switches and second switches across four channels) to deliver combined current output. This merging approach maintains portability while managing complexity through centralized control logic that selectively activates and coordinates the multiple battery channels.
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
The battery-powered system reduces the size and weight of the welding equipment, significantly lowers noise levels, and improves fuel efficiency, allowing for more versatile and quieter welding operations in various locations.
Implementation Method 1
a battery pack that includes a plurality of battery cells
Implementation Method 2
an engine-generator configured to output electrical power
Implementation Method 3
the energy storage device is discharged to create an arc between a stud that is connected to the weld stud gun and the work piece, thereby heating up the stud and the work piece
Data Source
AI summary
A stud welder for a stud welding system includes a battery pack that includes a plurality of battery cells, an input module configured to receive charging current from an engine-generator and selectively provide the charging current to the battery cells of the battery pack, an output module configured to selectively output a welding current from the battery cells of the battery pack, and a controller configured to selectively supply the welding current to a stud weld gun of the stud welder.