DC Input Welding Circuit for Isolated Distributed Power Buses
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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, incorporating a DC plug and internal circuitry to handle and process the DC power, including a contactor circuit for protection, a filter circuit for voltage adjustment, and a DC/DC converter to generate appropriate welding power, while also providing auxiliary power to associated tools and devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If welding systems are designed for AC power distribution, then compatibility with traditional power systems is improved, but adaptability to DC power distribution deteriorates
Solution Approach 1:
The patent changes the fundamental power parameter from AC to DC, allowing the welding system to directly accept DC power from distributed power buses. This eliminates the need for AC-DC conversion circuitry while maintaining all essential welding functions, thereby improving adaptability to DC power distribution without proportionally increasing device complexity
Solution Approach 2:
The invention extracts and removes the unnecessary AC power conversion components (rectifiers, capacitors, and associated control circuitry) from traditional welding systems. By eliminating these redundant elements that are not needed when operating directly from DC power, the system achieves better DC adaptability with reduced overall complexity
2Use of energy by moving object
If AC power distribution is used, then ease of voltage transformation is improved, but energy efficiency deteriorates due to additional conversion stages
Solution Approach 1:
The patent removes unnecessary AC-DC conversion stages from the power pathway. By designing the welding system to operate directly from DC power distribution, it eliminates rectifiers, filtering capacitors, and associated control circuitry, thereby reducing energy losses and improving overall energy efficiency without adding significant complexity
Solution Approach 2:
The invention enables continuous, direct power delivery from DC distribution buses to the welding system without interruption or conversion. This continuous power flow eliminates the energy losses associated with AC-DC conversion stages while maintaining simple system architecture
3Use of energy by moving object
If DC power distribution is implemented, then energy efficiency is improved by removing conversion stages, but compatibility with existing welding systems deteriorates
Solution Approach 1:
The patent fundamentally changes the power input parameter from AC to DC, making the welding system natively compatible with DC power distribution. This design choice improves energy efficiency by eliminating conversion stages while establishing new compatibility standards for DC-powered welding applications
Solution Approach 2:
The invention creates a universal DC-powered welding system that can operate with various DC power sources including distributed power buses, rectified power supplies, and battery systems. This multi-functionality approach improves compatibility across different DC power environments while maintaining high energy efficiency
4Ease of manufacture
If conventional AC input welders are used, then availability of equipment is improved, but heat generation from conversion components increases
Solution Approach 1:
The patent extracts and eliminates the heat-generating AC-DC conversion components (rectifiers, capacitors, and control circuitry) from the welding system. By operating directly from DC power, the system removes these harmful heat sources while simplifying the overall equipment design and improving reliability
Data Source
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.