Bidirectional AC-DC Converter Layout for Hybrid Welding Power Supplies

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Solution Overview

Problem

Conventional engine-driven and hybrid welding power supplies experience increased conversion losses and reduced efficiency due to multiple power conversion stages, which also increase the likelihood of system failures.

Innovation Solution

Hybrid welding-type power supplies with bidirectional AC-DC converters reduce the number of power conversion stages by integrating an AC bus that couples different input sources and output modules, utilizing an energy storage device, power conversion circuitry, and a bidirectional AC-DC converter to minimize conversions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple power conversion stages are used in conventional welding power supplies, then the system can provide multiple output types (AC and DC), but conversion losses increase and efficiency decreases

Engineering Contradiction:

Improveoutput typesVSAvoidconversion losses

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent combines multiple power conversion functions into a single bidirectional AC-DC converter that can operate in different modes (AC-to-DC conversion for welding output, DC-to-AC conversion for auxiliary output). This single converter replaces what would traditionally require separate conversion stages, reducing cumulative conversion losses while maintaining the ability to provide both AC and DC outputs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bidirectional AC-DC converter dynamically switches between different conversion modes based on operational requirements. It can convert AC input to DC for welding outputs, or convert DC from the energy storage device to AC for auxiliary outputs. This dynamic operation allows the system to maintain versatility while minimizing conversion stages in each specific operational mode.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple power conversion stages are used in conventional welding power supplies, then the system can provide multiple output types (AC and DC), but the likelihood of system failures increases

Engineering Contradiction:

Improveoutput typesVSAvoidsystem failures

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By merging multiple conversion functions into a single bidirectional AC-DC converter, the patent reduces the total number of conversion stages and associated components. Fewer stages mean fewer potential failure points, thereby improving system reliability while still enabling both AC and DC output capabilities through the converter's bidirectional operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bidirectional AC-DC converter serves multiple functions: it performs AC-to-DC conversion for welding outputs, DC-to-AC conversion for auxiliary outputs, and can operate in regenerative modes. This multi-functionality in a single device reduces the number of specialized components needed, thereby reducing the overall likelihood of system failures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of energy

If a bidirectional AC-DC converter is used to reduce power conversion stages, then efficiency increases and failures are reduced, but the device complexity increases

Engineering Contradiction:

Improveconversion lossesVSAvoidconverter configuration

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The bidirectional AC-DC converter is designed as a universal component that handles multiple conversion directions (AC-to-DC and DC-to-AC) and multiple operational modes (welding output, auxiliary output, regenerative operation). By consolidating these functions into a single multi-functional device, the patent reduces the total number of components and conversion stages, thereby reducing overall system complexity despite the advanced functionality of the converter itself.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This configuration enhances efficiency and reduces the likelihood of failures by minimizing power conversion stages, allowing for seamless integration of AC and DC power sources and outputs, and optimizing power supply operations.

Implementation Method 1

a bidirectional AC-DC converter configured to transform the AC input power to output DC power to the energy storage device, and to transform DC power from the energy storage device to output AC power

Methodology Applied

Scientific EffectPower conversion:

Data Source

PatentUS20250367747A1Hybrid welding-type power supplies having bidirectional ac-DC converters

Publication Date: 2025.12.04 ILLINOIS TOOL WORKS INC

AI summary

Disclosed example welding-type power supplies include: an energy storage device; an AC auxiliary output to output AC output power based on AC input power; power conversion circuitry configured to convert the AC input power to DC output power; and a bidirectional AC-DC converter configured to convert the AC input power to output DC power to the energy storage device, and to convert DC power from the energy storage device to output AC power as the AC input power to the AC auxiliary output and the power conversion circuitry.