External Cooling Layout for Compact Welding Power Supplies
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Solution Overview
Problem
Welding current sources for arc welding processes face challenges in managing high thermal heat losses, leading to large housing sizes due to internal cooling and inductance devices, which obstruct efficient heat dissipation and increase the risk of electronics damage.
Innovation Solution
The cooling and inductance devices are relocated to the outer side of the housing, allowing for a significantly smaller housing design by eliminating internal space requirements and enabling quick and effective heat dissipation through external convection and fan-assisted airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the cooling device and inductance device are arranged inside the housing, then the housing provides protection and integration, but the housing size becomes large and heat dissipation is impeded
Solution Approach 1:
The cooling device and inductance device are extracted from the internal housing space and repositioned to an external mounting location. This extraction eliminates the volume these components occupied within the housing, directly reducing the housing size while simultaneously improving heat dissipation efficiency by positioning the cooling device externally where it can more effectively dissipate thermal heat losses to the surrounding environment.
2Volume of stationary object
If the cooling device and inductance device are arranged inside the housing, then the components are integrated, but the housing requires additional clearance and fastening materials that increase its size
Solution Approach 1:
By extracting the cooling device and inductance device from the housing interior, the patent eliminates the need for internal clearance zones and fastening materials that would otherwise be required to secure these components within the housing structure. This directly reduces the housing volume without compromising component functionality or protection.
Solution Approach 2:
The cooling device is merged with the housing outer side, creating an integrated external assembly. This merging eliminates the need for separate internal mounting structures and fastening materials, as the cooling device becomes part of the housing's external structure rather than an internal component requiring additional clearance and attachment mechanisms.
3Reliability
If the cooling device is internal, then the housing maintains a compact appearance, but heat buildup occurs and electronics are at risk
Solution Approach 1:
The cooling device is extracted from the housing interior and positioned externally, enabling it to more effectively dissipate thermal heat losses to the surrounding environment. This extraction directly improves reliability by preventing heat buildup that could damage electronics, while simultaneously reducing the housing size by eliminating the volume previously occupied by the cooling device and required clearance spaces.
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
This configuration reduces the housing size while ensuring reliable protection of the inductance device and enhancing heat dissipation, preventing heat buildup and allowing for unimpeded airflow, thus maintaining efficient operation and preventing electronics damage.
Implementation Method 1
enabling quick and effective heat dissipation through external convection and fan-assisted airflow
Implementation Method 2
enabling quick and effective heat dissipation through external convection and fan-assisted airflow
Implementation Method 3
an inductance device of the current transformer device
Data Source
AI summary
A welding current source for supplying an electric welding current circuit with electric current and electric voltage for carrying out an electric welding process, wherein the welding current source is provided with a power conditioning device for conditioning electric current supplied to the welding current source for suitability in an electric welding process, wherein furthermore on a housing of the welding current source there are provided two pole contact devices, each of which protrude from the housing, and the welding current source is equipped with a cooling device, with which thermal heat loss released by the welding current source can be dissipated. In the case of such a welding current source and despite sufficient cooling of the electrical components, it shall be possible that the housing of the welding current source can be designed to be also smaller than before.