Engine Driven Welding Machine Idle Stop Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional engine-driven welding machines have high fuel consumption and CO2 emissions, produce noise, and lack efficient remote engine stop and restart capabilities, especially in high-rise settings where manual operation is cumbersome.
Innovation Solution
An engine-driven welding machine with an engine stop signal forming circuit, voltage detecting means, and restart detecting circuit that uses voltage changes from short-circuit and opening of output terminals to reliably stop and restart the engine, ensuring efficient idle operation and reduced fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the engine shifts to idle operation every time welding is stopped, then fuel consumption and noise are reduced, but the engine runs wastefully at idle when welding is stopped for long periods
Solution Approach 1:
The control circuit continuously monitors the welding operation state through voltage detection and automatically adjusts engine operation mode (standard operation, idle operation, or stop) based on real-time feedback, eliminating the need for manual intervention and optimizing fuel consumption
Solution Approach 2:
The welding machine performs self-control of engine operation through automatic detection of welding state and autonomous switching between operation modes, enabling the system to manage its own power consumption without external intervention
2Loss of energy
If the operator manually stops the engine when welding is stopped for long periods, then fuel consumption is reduced, but this is troublesome and inefficient especially in high-rise settings
Solution Approach 1:
The welding machine automatically monitors welding operation state and controls engine start/stop/idle transitions without requiring operator intervention, eliminating the inconvenience of manual engine management especially in difficult-to-reach locations
Solution Approach 2:
The control circuit continuously detects welding state through voltage monitoring and automatically makes decisions about engine operation mode, providing intelligent self-management that removes the burden of manual operation from the user
3Ease of operation
If remote control is implemented using touch sensor or noise filter, then engine stop is easier, but the touch sensor may be lost and the noise filter is not widely used
Solution Approach 1:
The welding cable serves multiple functions: it provides welding current transmission and simultaneously acts as a communication medium for control signals, eliminating the need for separate control devices like touch sensors or noise filters while ensuring reliable signal transmission
Solution Approach 2:
The control signal transmission function is merged with the existing welding cable infrastructure, combining power transmission and control functions into a single reliable medium that is already present at the operation site
4Productivity
If the engine is restarted automatically upon voltage change, then welding operation can start quickly, but the engine may restart unnecessarily due to false voltage signals
Solution Approach 1:
The control circuit performs preliminary detection and verification of voltage change patterns before triggering engine restart, analyzing the sequence and characteristics of voltage changes to distinguish genuine welding start signals from false signals
Solution Approach 2:
The system continuously monitors voltage changes and uses feedback analysis to determine whether a voltage change represents a genuine welding operation start, preventing false restarts while enabling quick response to legitimate welding commands
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An engine driven welding machine which is favorable in operability and has high reliability and reliably performs idle stop and restart is provided. An engine driven welding machine in which a welding generator (9) is driven by an engine (E), and the aforesaid engine performs an idle operation when a welding operation is stopped is characterized by including an engine stop signal forming circuit (IT) which forms a stop signal for stopping an operation of the aforesaid engine when time of the aforesaid idle operation exceeds a predetermined time, a direct-current power supply (PS) connected to an output terminal of the aforesaid welding machine, voltage detecting means (VS) which detects a voltage change of the aforesaid output terminal, a restart detecting circuit (RS) which forms a restart signal for restarting the aforesaid engine when the detected voltage by the aforesaid voltage detecting means shows a predetermined change mode for starting the welding operation, and an engine control circuit (EC )which stops the aforesaid engine in response to the aforesaid stop signal, and restarts the aforesaid engine in response to the aforesaid restart signal.