Hybrid Welding Power Supply for Interchangeable Battery Inputs
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Solution Overview
Problem
Battery-powered welding tools are costly due to the high expense of batteries, which are often specific to the tool and not interchangeable between brands, limiting reuse and increasing the need for repeated purchases.
Innovation Solution
Hybrid welding systems and power supplies that utilize power conversion circuitry to convert power from various batteries, allowing operators to use existing batteries from other tools, including lawn equipment, to supply welding power, reducing the need for dedicated batteries and enhancing battery reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery-powered welding sources are designed with specific battery configurations, then welding power and performance are improved, but battery interchangeability and cost-effectiveness deteriorate
Solution Approach 1:
The welding power supply is designed with a universal battery interface that can accept multiple battery types and configurations. The system includes a battery management system that automatically detects and adapts to different battery chemistries, voltages, and capacities, allowing the same welding machine to function with various battery sources without requiring model-specific designs.
Solution Approach 2:
The power supply incorporates adjustable parameters including voltage ranges (18V-54V), current limits, and power output settings that can be dynamically modified based on the connected battery's characteristics. This allows the system to optimize welding performance for each battery type while maintaining safety and compatibility across different battery specifications.
2Reliability
If dedicated batteries are required for welding tools, then welding performance and reliability are improved, but cost and financial burden increase
Solution Approach 1:
The system enables a single welding power supply to serve multiple functions by accepting different battery types for different applications. Users can employ high-capacity batteries for extended welding tasks and lower-capacity batteries for shorter jobs, reducing the need to purchase multiple dedicated battery packs while maintaining reliable performance across all scenarios.
Solution Approach 2:
The battery management system automatically monitors battery health, charge status, and compatibility, providing real-time feedback to the user. The system self-adjusts operating parameters based on the connected battery's state, eliminating the need for users to manually configure settings or purchase specialized batteries for different welding requirements.
3Power
If high-power batteries are used for welding operations, then welding capability and output are improved, but battery cost and purchase frequency increase
Solution Approach 1:
The welding power supply features dynamic power management that adjusts output based on the connected battery's capacity and state of charge. The system can operate at high power levels when a large-capacity battery is connected and automatically reduces power consumption when smaller batteries are used, maximizing the utility of each battery while maintaining welding effectiveness.
Solution Approach 2:
The system allows users to connect multiple batteries in parallel to achieve higher capacity and extended runtime without requiring a single large, expensive battery. This partial action approach enables users to build the required power and capacity incrementally using smaller, more affordable battery units that can be combined to meet welding demands.
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
Enables cost-effective welding operations by allowing the use of existing batteries, increasing the versatility of battery-powered welding tools and reducing the financial burden of dedicated batteries, while supporting a range of welding tasks with adaptable power conversion.
Implementation Method 1
a bidirectional DC-DC converter configured to convert power from the battery from a first voltage to an intermediate voltage
Data Source
AI summary
Disclosed example welding-type power supplies include: a first DC/DC converter configured to convert a first voltage from a first energy storage device to an intermediate voltage, and to output the intermediate voltage to an intermediate bus; a second DC/DC converter configured to convert a second voltage from a second energy storage device to the intermediate voltage, and to output the intermediate voltage to the intermediate bus; power conversion circuitry configured to convert the intermediate voltage to a welding-type output; and control circuitry configured to: control the first DC/DC converter based on the first voltage and the intermediate voltage; control the second DC/DC converter based on the second voltage and the intermediate voltage; and control the power conversion circuitry.