Hybrid Welding Power Control for Battery Capacity Limits
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Solution Overview
Problem
Conventional welding power supplies are limited by their rated output, and battery-assisted systems require reconfiguration between charging and welding, lacking operator guidance and efficient energy management.
Innovation Solution
Hybrid welding systems with control circuitry and monitoring capabilities to determine utility power and battery conditions, providing operator guidance and optimizing welding parameters based on available energy sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery-assisted systems are integrated with welding power supply, then welding capacity is increased, but system complexity increases and requires reconfiguration between charging and welding
Solution Approach 1:
The patent combines the welding power supply and battery system into a single integrated unit with shared housing and control circuitry. The power conversion circuitry handles both grid-to-battery charging and battery-to-welding power conversion, eliminating the need for separate systems and reducing overall complexity despite the hybrid functionality.
Solution Approach 2:
The power conversion circuitry is designed to perform multiple functions: rectifying grid power for battery charging, converting battery power for welding output, and providing auxiliary power to the control system. This multi-functionality eliminates the need for separate charging and welding systems, reducing complexity while maintaining increased welding capacity.
2Ease of operation
If conventional battery-assisted systems require reconfiguration between charging and welding, then energy management is simplified, but productivity decreases due to operational interruptions
Solution Approach 1:
The control system continuously monitors battery state of charge and automatically manages power flow between grid charging and welding operations without requiring operator intervention or system reconfiguration. This continuous operation eliminates interruptions and maintains productivity while keeping the system easy to operate through automatic energy management.
Solution Approach 2:
The control circuitry continuously monitors battery charge levels, grid power availability, and welding power demands, automatically adjusting power flow to optimize both ease of operation and productivity. The system provides real-time feedback to the operator through the user interface while autonomously managing the complex energy routing decisions.
3Manufacturing precision
If hybrid welding systems provide operator guidance and optimize welding parameters, then welding quality improves, but device complexity increases
Solution Approach 1:
The control system automatically monitors battery state of charge and autonomously optimizes welding parameters such as current limits and power distribution without requiring operator expertise or manual configuration. This self-service capability improves welding quality through precise parameter control while maintaining operational simplicity for the user.
Solution Approach 2:
The system replaces manual operator judgment and mechanical adjustment with electronic sensors and digital control algorithms that automatically monitor battery conditions and adjust welding parameters. This substitution of electronic control for manual operation improves precision while keeping the user interface simple and intuitive.
4Ease of manufacture
If conventional welding power supplies operate at rated output, then design is simplified, but adaptability to different energy sources decreases
Solution Approach 1:
The power conversion circuitry dynamically adapts its operation mode based on real-time conditions: switching between grid-only charging, battery-only welding, and hybrid combined modes. This dynamic adaptability allows the system to efficiently utilize different energy sources while maintaining a relatively simple fixed design architecture.
Solution Approach 2:
The control system changes operational parameters such as power conversion ratios, current limits, and voltage levels based on the available energy source and welding requirements. This parameter adaptability enables the system to work with different battery capacities and grid conditions without requiring fundamental design changes, balancing simplicity with versatility.
Data Source
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AI summary
Disclosed example welding systems comprise: a power input configured to receive input power from batteries; power conversion circuitry configured to convert the input power from the batteries to welding power; a user interface configured to input one or more parameters for the welding power; a battery monitor configured to determine properties of the batteries; and control circuitry configured to: determine a welding capacity associated with the parameters for the welding power and based on the determined properties of the batteries; in response to determining that the welding capacity does not support the parameters for the welding power, output an indication representative of limitations on the parameters for the welding power based on the welding capacity; in response to determining that the welding capacity supports the parameters for the welding power, output an indication of remaining welding capacity; and control the power conversion circuitry based on the parameters.