Compressed Air Cooling for High-Power Welding Electronics

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Solution Overview

Problem

Conventional welding systems face challenges with high power outputs that generate heat, compromising system performance and requiring substantial equipment investments.

Innovation Solution

The integration of compressed air cooling within welding systems, where compressed air is routed through the system to cool components such as power conversion circuitry, thereby drawing heat away and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If high power output is used in welding systems, then welding performance is improved, but heat generation increases compromising system performance

Engineering Contradiction:

Improvepower outputVSAvoidheat generation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent converts the harmful heat generated by high power welding operations into a beneficial cooling mechanism by routing compressed air through cooling channels in the power conversion circuitry. The compressed air absorbs heat from the components, transforming the thermal problem into a functional cooling solution that enables sustained high power operation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Compressed air serves as an intermediary cooling medium between the heat-generating power conversion circuitry and the external environment. The air is routed through channels in the circuitry, absorbing heat and transporting it away from critical components, thereby mediating the thermal management process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If conventional cooling systems are added to welding systems, then cooling capability is improved, but system weight and cost increase

Engineering Contradiction:

Improvecooling capabilityVSAvoidsystem weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The compressed air system performs multiple functions: it provides cooling for power conversion circuitry during welding operations and simultaneously serves as the operational medium for carbon arc gouging processes. This multi-functionality eliminates the need for separate dedicated cooling systems, reducing overall system weight and complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its own operational compressed air supply to provide cooling services to the power conversion circuitry. Rather than requiring an external or separate cooling system, the welding system self-cools by routing the compressed air that is already part of its operational requirements through cooling channels in the electronics.

Inventive Principle:

Principle #25Self-service

3Temperature

If conventional cooling systems are added to welding systems, then cooling capability is improved, but system cost increases

Engineering Contradiction:

Improvecooling capabilityVSAvoidsystem cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the cooling function with the existing compressed air delivery system for carbon arc gouging. By combining these two functions into a single integrated system with shared infrastructure (compressor, air lines, and distribution), the patent reduces the number of separate components needed, thereby lowering manufacturing costs and simplifying assembly.

Inventive Principle:

Principle #5Merging (Combining)

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 solution provides effective cooling, reducing the weight and cost of welding systems, extending their useful life, and enhancing operational efficiency across various environments.

Implementation Method 1

Routing compressed air near the components will introduce relatively cool air to the environment. As the passing compressed air heats in response to interaction with the heated components, heat is drawn from the components and/or the nearby environment.

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

compressed air is routed within the welding system to provide cooling for one or more components therein... conveyance of the compressed air draws heat from the component

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12280450B2Integrated compressed air cooling for welding systems

Publication Date: 2025.04.22 ILLINOIS TOOL WORKS INC

AI summary

Systems and methods are disclosed for integrated compressed air cooling for welding systems. In particular, the disclosed systems and methods may employ compressed air to implement one or more welding processes (e.g., a gouging or cutting processes), with the compressed air being conveyed through such welding systems. In some examples, the compressed air is routed within the welding system to provide cooling for one or more components therein. For instance, components such as power conversion circuitry may heat up during the welding process. Routing compressed air to or near the components will introduce relatively cool air to the environment. As the passing compressed air heats in response to interaction with the heated components, heat is drawn from the components and/or the nearby environment.