DC Bus Welding Power Input Without AC Conversion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing welding systems are predominantly designed for alternating current (AC) power distribution, whereas there is a growing need for systems that can efficiently operate with direct current (DC) power distribution, which is becoming more prevalent in industrial applications.

Innovation Solution

A DC input welder system that can receive and utilize DC power directly from a DC power distribution system, eliminating the need for conventional power conversion circuitry and including features like a DC plug, internal circuitry for handling DC power, and a controller for managing welding parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If welding systems are designed for AC power distribution, then they can utilize conventional AC power infrastructure, but they require additional power conversion circuitry when DC power is provided, increasing device complexity and reducing efficiency

Engineering Contradiction:

Improvecompatibility with conventional AC power infrastructureVSAvoidpower conversion circuitry

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent inverts the conventional approach by designing welding systems that accept DC power directly instead of AC power. This eliminates the need for AC-to-DC conversion circuitry, reducing device complexity and improving efficiency while maintaining compatibility with modern DC power distribution infrastructure.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the fundamental power parameter from AC to DC, allowing the welding system to operate directly from DC power sources. This parameter change eliminates the need for rectification and filtering circuits, simplifying the overall system design while enabling efficient operation with modern DC power distribution systems.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If AC power distribution is used, then voltage transformation is easy using transformers, but power loss increases during transmission over long distances

Engineering Contradiction:

Improvevoltage transformation capabilityVSAvoidtransmission loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical transformer-based voltage transformation system with electronic DC-DC conversion circuitry. This substitution eliminates the inherent energy losses associated with transformer operation and long-distance AC transmission, while still providing flexible voltage transformation capability through solid-state power electronics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If DC power distribution is implemented, then power conversion stages are reduced and efficiency improves, but existing welding systems require redesign to accept DC input

Engineering Contradiction:

Improvepower conversion lossVSAvoidsystem redesign requirement

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent fundamentally changes the power input parameter from AC to DC, enabling direct connection to DC power distribution systems. This parameter change eliminates unnecessary power conversion stages, reducing energy loss and improving overall system efficiency, while the redesign is facilitated by modern DC-DC conversion technologies.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If conventional AC-powered welders are used with DC power, then existing equipment can be utilized, but additional power conversion components are required, increasing cost and reducing efficiency

Engineering Contradiction:

Improveequipment compatibilityVSAvoidpower conversion inefficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent inverts the conventional equipment design approach by creating welders that natively accept DC power input instead of AC power. This inversion eliminates the need for AC-to-DC conversion components, reducing both energy loss and equipment cost, while maintaining full adaptability to modern DC power distribution systems.

Inventive Principle:

Principle #13The other way round (Inversion)

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 DC input welder system reduces the need for additional power conversion components, enhances efficiency, and allows for cost-effective operation with DC power, making it suitable for various welding applications, including stick, TIG, and MIG welding, while providing auxiliary power for tools and equipment.

Implementation Method 1

rely upon the creation of a welding arc to melt and fuse base metals and/or adder metals

Methodology Applied

Scientific EffectElectric arc: Electric Arc

Implementation Method 2

circuitry configured to receive DC power directly from a distributed DC bus, to generate a current using the received DC power

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240009749A1Welding system utilizing a distributed power bus

Publication Date: 2024.01.11 ILLINOIS TOOL WORKS INC

AI summary

In certain embodiments, a system includes a welding-type system including circuitry configured to receive direct current (DC) power directly from a distributed DC bus, to generate a current using the received DC power, and to isolate the welding-type system from the distributed DC bus.