Battery-Powered Portable Welder With Runtime Prediction and Lockout
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Solution Overview
Problem
Existing portable welders lack efficient power management systems, wireless communication capabilities, and safety features, limiting their usability and efficiency in welding operations.
Innovation Solution
Incorporating a removable and rechargeable battery pack interface, a buck converter for voltage control, a wireless communication controller, and a security lockout system, along with temperature-controlled fan operation and runtime prediction, to enhance power management, connectivity, and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a removable and rechargeable battery pack is used to power the portable welder, then portability and ease of operation are improved, but the duration of action and energy availability are limited
Solution Approach 1:
The welder system dynamically adapts to battery power limitations by implementing temperature-controlled fan operation (turning fan on/off based on temperature thresholds) and providing runtime predictions to users. The system monitors battery state-of-charge and adjusts operational parameters to maximize usable runtime while maintaining welding functionality.
2Reliability
If power management features like temperature-controlled fan and runtime prediction are added, then reliability and ease of operation are improved, but device complexity increases
Solution Approach 1:
The welder system performs self-monitoring and self-adjustment through automated temperature sensing that controls fan operation and battery state-of-charge monitoring that provides runtime predictions. These self-service functions reduce the need for user intervention while maintaining reliable operation, managing complexity through automation rather than manual controls.
3Adaptability or versatility
If wireless communication capability is added to control welder settings, then ease of operation and adaptability are improved, but device complexity increases
Solution Approach 1:
A wireless communication controller serves as an intermediary between external devices and the welder's control system. This mediator handles all wireless communications and setting adjustments, allowing users to control welder parameters remotely without adding complex user interface elements to the physical device. The intermediary manages the complexity internally while providing simple external access.
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 efficient power utilization, wireless communication with external devices, and improved safety features, enhancing the usability and performance of portable welders.
Implementation Method 1
a voltage output of the portable welder is controlled using a voltage converter. In some aspects, the converter is a buck converter.
Data Source
AI summary
A portable welder that includes a portable housing, a ground clamp, an electrode holder, a user interface, and a battery pack interface. The ground clamp is connected to the portable housing through a ground cable and is configured to be connected to a metal workpiece. The electrode holder is connected to the portable housing through an electrode cable. The electrode holder includes a mount connected to the electrode cable and a user input. The mount is configured to hold a consumable electrode. The user input is configured to activate the portable welder. The user interface located on the housing. The battery pack interface is configured to receive a removable and rechargeable battery pack.