Dual Battery Hybrid Welder Engine Drive Control
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Solution Overview
Problem
Conventional hybrid engine drive welders face limitations in reliability, performance, and versatility due to inefficiencies in power distribution and energy storage, leading to compromised usability and reduced battery life.
Innovation Solution
A hybrid engine drive welder system utilizing a first energy storage device for engine startup and a second energy storage device, such as a lithium-ion battery, to manage power loads, with multiple operational modes adjusting engine usage based on load demand, allowing the battery to supply power during welding and recharging, thereby optimizing energy efficiency and extending battery life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single battery is used to both start the engine and provide power for welding operations, then the system structure is simpler, but the battery life is reduced and reliability is compromised
Solution Approach 1:
The power supply system is segmented into two distinct batteries: a first battery (starter battery) dedicated to engine starting operations, and a second battery (deep cycle battery) dedicated to welding operations and auxiliary power. This segmentation prevents the single battery from being overworked, extending its life and improving system reliability.
2Reliability
If the engine runs continuously to provide power, then power availability is ensured, but noise and exhaust emissions increase
Solution Approach 1:
The engine operates periodically rather than continuously - it runs to generate electricity that charges the second battery and powers the inverter welder during welding operations, then shuts off during idle periods. This periodic operation reduces noise and exhaust emissions while maintaining power availability when needed.
Solution Approach 2:
The second battery acts as an intermediary energy storage device between the engine/generator and the welding load. It decouples the engine operation from the welding operation, allowing the engine to run efficiently and charge the battery, then the battery to supply power during welding without requiring continuous engine operation, thereby reducing noise and exhaust.
3Power
If a larger battery is used to provide sufficient power for welding, then power capacity is increased, but battery life is reduced due to deep cycling
Solution Approach 1:
The system segments the power delivery function from the engine/alternator to the second battery, which is specifically designed as a deep cycle battery capable of handling repeated charge/discharge cycles. This allows the use of a battery optimized for cycling applications rather than a standard starter battery, extending life while maintaining adequate power capacity for welding operations.
4Power
If the engine is sized to provide maximum power output, then peak power demand is met, but the engine size and weight increase
Solution Approach 1:
The engine is sized to provide only the necessary power to charge the second battery and run auxiliary loads, rather than being oversized to directly meet peak welding power demands. The battery provides the additional power capacity needed for peak welding loads, allowing the engine to be smaller and lighter while still meeting overall system power requirements.
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 system enhances reliability and versatility by optimizing energy usage, reducing the size and cost of engine and generator components, improving efficiency, and enabling quieter operation by minimizing engine usage, while extending the life of energy storage devices.
Implementation Method 1
uses a first energy storage device to start an engine of the welder
Implementation Method 2
a second energy storage device, which can be a lithium ion battery, to provide power for all other power loads for the welder
Implementation Method 3
an engine and generator combination are used to generate power
Data Source
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AI summary
Embodiments of the present invention are directed to a combustion engine power generation device, such as an engine driven welder, which utilizes a first battery for engine start and providing operational power when the system is off, and a second high storage battery to provide all operational power so long as the second battery has the stored energy to supply the needed power. In an embodiment, the first battery is a lead acid battery and the second battery is a lithium ion battery.