Cordless Welding Machine Parallel Battery Configuration

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Solution Overview

Problem

Conventional welding machines are cumbersome and difficult to move due to their weight and reliance on AC power sources, making them impractical for use in different locations without access to nearby power.

Innovation Solution

A cordless welding machine design utilizing multiple lithium-ion battery packs connected in parallel, providing a high current output and enabling a lightweight, portable welding solution with a power-to-weight ratio that allows for extended use without the need for external power sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional welding machines are used, then reliable welding function is achieved, but weight and portability are compromised

Engineering Contradiction:

Improvewelding machine weightVSAvoidwelding function reliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The welding machine is divided into separate modular components: battery packs, welding power supply unit, and ground clamp. This segmentation allows the heavy AC-powered units to be replaced with lightweight battery packs, reducing overall machine weight while maintaining welding functionality through modular reconfiguration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The power source parameter is changed from AC mains power to battery power. This parameter change fundamentally alters the weight characteristics while maintaining the essential welding function, enabling portability without sacrificing core operational capability.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If AC power sources are used, then sufficient power output is achieved, but mobility and adaptability are reduced

Engineering Contradiction:

Improvelocation adaptabilityVSAvoidcurrent output

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The welding machine is designed with universal power input capability, accepting both AC mains power and battery power. This multi-functionality allows the same welding unit to operate in diverse locations - either plugged into AC power or powered by portable battery packs - thereby achieving both high power output and location adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If battery packs are used, then portability is improved, but current output capacity must be increased to maintain welding quality

Engineering Contradiction:

ImproveportabilityVSAvoidcurrent output

Core Design Contradiction:

Ease of operationVSPower

Solution Approach 1:

Multiple battery packs are combined in parallel configuration to achieve high current output capacity. This merging of multiple power sources provides sufficient amperage for quality welding while maintaining the portability benefits of battery power, as the individual battery packs remain lightweight and removable.

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

The cordless welding machine achieves a significant reduction in weight, allowing for easier portability and increased mobility, while maintaining high current output, and reduces AC power requirements, enabling use with standard household outlets and longer cord lengths without voltage drop.

Implementation Method 1

first and second batteries being connected in parallel... the batteries providing a current output of at least about 40 amps

Methodology Applied

Scientific EffectElectrochemical energy conversion: Battery (electricity)

Data Source

PatentUS9533367B2Cordless welding machine and plasma cutter

Publication Date: 2017.01.03 BLACK & DECKER CORP

AI summary

A cordless welding machine includes first and second batteries being connected in parallel, a ground clamp connected to the first and second batteries, and a first welding electrode connected to the first and second batteries. The batteries providing a current output of at least about 40 amps.