Battery Welder Display for Remaining Weld Count Prediction
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Solution Overview
Problem
Conventional battery welders lack the ability to intuitively and accurately determine how long a welding operation can be continued based on the remaining battery capacity, especially when the welding current is adjusted, making it difficult to plan the welding work effectively.
Innovation Solution
A battery welder equipped with a computation and display device that calculates and displays the number of welding rods that can be completed using the current battery capacity, considering the set welding current and battery condition, utilizing a battery management system to monitor and compute the precise number of welds possible.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the welding current is adjusted to meet different welding needs, then the adaptability of the welding machine is improved, but the ability to accurately determine remaining work capacity is worsened
Solution Approach 1:
The system continuously monitors the actual welding current and integrates it over time to calculate consumed battery capacity. This feedback mechanism updates the remaining work capacity display in real-time, ensuring accurate information is provided despite welding current adjustments. The feedback loop includes sensing the actual current, computing consumed capacity, and displaying updated remaining capacity.
Solution Approach 2:
The system pre-calculates the relationship between welding current values and power consumption, and between battery capacity and number of welds. This preliminary computation allows the system to quickly determine remaining work capacity without complex real-time calculations, providing immediate feedback to the operator.
2Ease of operation
If the remaining battery capacity is displayed simply, then the ease of operation is improved, but the precision of work planning information is worsened
Solution Approach 1:
The remaining work capacity information is segmented into multiple display modes: a simple numerical value showing the number of welds for quick reference, and detailed information showing the relationship between welding current settings and remaining capacity. This segmentation allows operators to choose the appropriate level of detail for their current needs.
Solution Approach 2:
The system adds a new dimension to the display by showing not just the remaining capacity value, but also the correspondence between different welding current values and the number of welds achievable at each setting. This multi-dimensional information presentation enables both simple and precise interpretation of the same data.
3Device complexity
If the battery capacity computation is simplified, then the device complexity is reduced, but the accuracy of welding output prediction is worsened
Solution Approach 1:
The system performs preliminary computations to establish the relationship between welding current values and power consumption, and between battery capacity and number of welds. These pre-calculated relationships are stored and used during operation, avoiding complex real-time calculations while maintaining prediction accuracy.
Solution Approach 2:
The system changes the computational parameters from complex physical models to simplified empirical relationships based on actual measured data. By using actual welding current measurements and integrating them over time, the system achieves accurate predictions with simpler computation than theoretical models would require.
Data Source
AI summary
There is provided a battery welder including: a welding output device to which a welding rod is connected; a welding control device configured to control a welding output by a set welding current value; a battery device configured to supply electric power to the welding output device via the welding control device; and a computation and display device configured to compute a battery condition of the battery device and display a computation result, and including a processor and a display device. The processor calculates a remaining battery capacity based on information acquired the from battery device, calculates a number of welding rods that can be welded based on a welding output for each of welding current values, and causes the display device to display the number of welding rods that can be welded.