Hybrid Welder Battery Engine Segmentation
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Solution Overview
Problem
Conventional electric arc welders that generate high welding currents require large, costly, and inefficient fuel-powered engines and generators, leading to increased size, weight, noise, pollution, and energy waste due to the need for constant maximum power production, even during low duty cycles.
Innovation Solution
The implementation of a hybrid energy source combining rechargeable batteries and alternative power sources like fuel cells or electric generators, allowing for a smaller engine size and improved energy efficiency by storing and using energy on demand, reducing waste, and enabling higher transient power capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large fuel-powered engine and electric generator are used to generate high welding currents, then the maximum welding output rating is achieved, but the size, weight, and cost of the welder significantly increase
Solution Approach 1:
The power generation function is segmented between the engine-driven generator and the battery power source. The engine and generator are sized to provide only the necessary supplemental power rather than the full maximum power, dividing the power delivery task between multiple sources to reduce individual component sizes and overall system weight.
Solution Approach 2:
The battery power source is pre-charged before welding operations begin. During low-duty-cycle periods, the battery provides the necessary power independently, so when welding demand arises, the power is already available without requiring the engine and generator to be continuously running at maximum capacity.
2Power
If a large fuel-powered engine is used to drive an electric generator, then high welding currents can be generated, but energy efficiency significantly decreases due to 60-80% idle time
Solution Approach 1:
The engine-driven generator operates periodically rather than continuously, activating only when the battery charge level drops below a threshold or when supplemental power is needed. This periodic operation aligns with the actual welding duty cycle, eliminating energy waste during the 60-80% idle time when full power is not required.
Solution Approach 2:
The battery power source serves itself by providing power during low-demand periods without requiring the engine to run, and the engine-generator system serves to recharge the battery when needed, creating a self-regulating system that automatically matches power generation to actual demand patterns.
3Power
If a large fuel-powered engine is used, then high welding currents are achieved, but noise and pollution levels significantly increase
Solution Approach 1:
The battery power source provides partial or complete power during low-duty-cycle welding operations, eliminating the need for the engine to run at partial load where it generates noise and pollution without providing proportional useful work. The engine operates only when necessary to recharge the battery or provide supplemental power during high-demand periods.
4Power
If the engine and generator are sized for maximum power output, then peak welding demands are met, but the initial cost significantly increases
Solution Approach 1:
The power delivery function is segmented between two separate systems: a smaller, less expensive battery power source for base power delivery, and a smaller engine-generator set for supplemental power and recharging. This segmentation allows both components to be sized more economically than a single large engine-generator would cost.
Solution Approach 2:
The system changes the operational parameters of power delivery by using the battery to provide base power and the engine-generator to provide only the differential power needed during welding operations. This parameter change allows the use of smaller, less expensive components while maintaining the same peak power 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
This approach results in a more energy-efficient, cost-effective, and versatile electric arc welder with reduced noise and pollution, capable of achieving high welding currents with smaller components and improved energy utilization, even during low duty cycles.
Implementation Method 1
The battery power source that is used by the electric arc welder is used as the principal energy source for supplying current for the electric arc
Implementation Method 2
an engine driven electric generator and at least one rechargeable battery. The electric generator generates an AC current
Implementation Method 3
The current generated by the electric generator is rectified to form a DC current
Implementation Method 4
Electric arc welders that generate more than 100 amps of welding current
Implementation Method 5
a welder that is rated to generate a 300-amp, 33.3 volt arc
Data Source
AI summary
An electric arc welder that includes a energy storage device and non-battery power source for the formation of an electric arc. The welder also includes battery charging circuit that controls the charging of the energy storage device by the non-battery power source. The non-battery power source can include an engine driven electric generator, power grid or a fuel cell.