Battery-Powered Welding Power Supply with Variable RPM Engine
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Solution Overview
Problem
Existing welding power supplies that use battery power are limited in providing long-term high power outputs and lack versatility, particularly in remote applications where AC auxiliary power is required, leading to inefficient engine-driven generators that consume excess fuel and cause noise due to fixed RPM operation.
Innovation Solution
A welding-type power supply system that includes a battery or energy storage device, a converter, and a controller with CV, CSC, and AC weld control modules, capable of converting battery power into welding-type and AC auxiliary power, allowing for efficient use of battery power and charging, while providing a versatile output suitable for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an engine-driven generator is used to provide welding power and AC auxiliary power in remote applications, then both welding power and AC auxiliary power are available, but the engine must run at fixed RPM above idle speed even when power demand is low, leading to excess fuel consumption and noise
Solution Approach 1:
The patent applies dynamics by enabling the engine to operate at variable RPM rather than fixed RPM. The controller monitors power demand and adjusts engine speed dynamically - running at higher speeds when welding power is needed and at lower speeds or idle when only AC auxiliary power is needed, thereby reducing fuel consumption and noise during low-demand periods
Solution Approach 2:
The patent implements multi-functionality by designing a single engine-driven generator system that can provide both welding power and AC auxiliary power. The system includes a converter that can output both welding current and AC voltage, allowing one engine to perform multiple functions rather than requiring separate engines for each purpose
2Adaptability or versatility
If an engine-driven generator operates at fixed RPM to provide fixed frequency AC auxiliary power, then AC power at standard frequency (50/60 Hz) is available, but the engine runs at speed well above idle even when total power demand is low, causing excess wear and fuel consumption
Solution Approach 1:
The system dynamically adjusts engine RPM based on actual power demand. When AC auxiliary power is the only load, the engine operates near idle speed. When welding power is required, the engine accelerates to higher RPM. This dynamic operation reduces engine wear by avoiding prolonged operation at high speeds when full power is not needed
3Object-generated harmful factors
If battery power is used to weld, then no engine is required, but battery power does not lend itself to long term high power outputs such as welding
Solution Approach 1:
The patent combines battery power and engine-driven generator power into a hybrid system. The battery provides immediate power for engine starting and can supplement during high-demand welding operations. The engine charges the battery and provides sustained power for long-duration welding tasks, creating a complementary relationship between the two power sources
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 system enables efficient use of battery power for welding and AC auxiliary applications, reducing fuel consumption and noise by allowing variable RPM operation, thus providing a reliable and versatile power solution for remote welding tasks.
Implementation Method 1
a converter connected to the battery and a controller that controls the converter to provide a welding-type power output
Data Source
AI summary
A method and apparatus provides welding-type power and preferably includes a removable battery or other energy storage device, a converter connected to the battery, and a controller. The controller may have a CV and/or a CSC and/or an AC weld control module, and/or an ac auxiliary control module. The converter is a boost converter, a buck converter, a cuk converter, a forward converter, an inverter, a bridge converter, and/or a resonant converter. The controller may include a battery charging control module, and may have one or more charging schedules, and/or data for stored charge, thermal information, expected life of the battery, maximum amp-hour charge for the battery, maximum charging current and/or feedback. The battery charging schedules may include at least 3 phases, such as a phase of increasing voltage and a phase of decreasing current, a substantially constant power phase. The controller can wirelessly provide data to a display or pda. A generator may provide power to the battery, charger, and/or the weld. It can include a vehicle and use its dc power system.