EV-to-Welder Charging Interface for Portable Generator-Free Welding
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Solution Overview
Problem
Conventional welding systems that draw power from engine-driven sources are cumbersome, heavy, and inefficient, and there is a need for a more portable and efficient power solution for welding operations, particularly in remote work environments.
Innovation Solution
A welding power system configured to receive input power from an electric vehicle's energy system using vehicle-to-grid (V2G) and vehicle-to-everything (V2X) protocols, incorporating power conversion circuitry and control circuitry to condition and manage power delivery for welding devices, eliminating the need for engine-driven generators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If welding systems draw power from engine-driven power sources, then sufficient power for welding operations is provided, but the system becomes cumbersome, heavy, and less portable
Solution Approach 1:
The patent replaces the mechanical engine-driven generator system with an electric vehicle's electrical power system. The EV battery and powertrain electrical system provides welding power without requiring a separate mechanical generator, thereby eliminating the weight and complexity of engine-driven power sources while maintaining sufficient power output for welding operations.
2Power
If engine-driven generators are used for mobile welding, then power availability is ensured, but environmental pollution and inefficiency increase
Solution Approach 1:
The invention substitutes the combustion-based engine-driven generator with an electric power source from an EV battery system. This replacement eliminates exhaust emissions and environmental pollution associated with internal combustion engines while ensuring continuous power availability for welding operations through the EV's high-capacity battery and power management system.
3Ease of operation
If conventional engine-driven power sources are used, then welding operations can be performed mobilely, but system complexity and maintenance requirements increase
Solution Approach 1:
The patent merges the welding power system with the electric vehicle's existing electrical powertrain system. By integrating the welding load into the EV's battery and power management infrastructure, the system eliminates the need for separate engine-driven generators and associated mechanical components, thereby reducing overall system complexity and maintenance requirements while preserving mobile welding capability.
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 solution provides a lightweight, emission-free, and efficient power source for welding operations, enhancing portability and reducing environmental impact while leveraging the high power density of electric vehicle batteries.
Implementation Method 1
incorporating power conversion circuitry and control circuitry to condition and manage power delivery for welding devices
Data Source
AI summary
Disclosed example welding power systems and methods are configured to receive input power from an energy system of electric vehicles (EV). In particular, the welding power system and/or the EV energy system can include adapters, power conversion circuitry, communications interfaces, and/or processing circuitry to facilitate power delivery and condition to the welding power system from the EV energy system. In some examples, the input power from the EV energy system is used to power welding operations directly. In some examples, the input power from the EV energy system is used to charge internal batteries of the welding power system, from which welding tools can draw power, while the welding power supply is connected to the EV Energy system and/or when the welding power supply is disconnected from the EV Energy system.