Hybrid Vehicle Welding Power via DC Bus
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Solution Overview
Problem
Conventional welding systems powered by internal combustion engines face issues with high emissions, noise, and fuel consumption, which are not effectively addressed by existing hybrid vehicle technologies that integrate intermittent welding capabilities.
Innovation Solution
A hybrid vehicle system that includes an engine and an energy storage device generating a direct current (DC) bus output, coupled with converter circuitry to power a welding device, allowing the welding system to utilize the hybrid vehicle's power efficiently, with various configurations such as series, parallel, and series-parallel drivetrains to optimize power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a conventional internal combustion engine powers welding operations, then welding capability is provided, but emissions and noise levels increase
Solution Approach 1:
The patent combines the welding system with a hybrid vehicle platform, merging the welding generator with the vehicle's existing engine and battery system. This integration allows the welding operations to utilize both the engine and battery power, reducing the need for the engine to run continuously at high emissions levels while maintaining welding capability.
Solution Approach 2:
The hybrid vehicle system serves multiple functions: it provides both locomotion and welding power. The engine and battery system is designed to support both vehicle operation and welding operations, allowing the same powertrain to fulfill multiple roles and reducing the need for dedicated welding equipment that would continuously emit pollutants.
2Productivity
If the vehicle engine runs continuously to power welding operations, then welding capability is maintained, but fuel consumption increases
Solution Approach 1:
The system uses periodic action by switching between battery power and engine power based on welding demands. The battery provides power during low-demand periods, and the engine supplements or takes over during high-demand welding operations, creating a periodic power delivery pattern that optimizes fuel usage compared to continuous engine operation.
Solution Approach 2:
The system changes the power delivery parameters by utilizing the battery's high power output capability for peak welding demands and the engine for sustained lower-power operations. This parameter optimization allows the system to meet welding power requirements while minimizing total fuel consumption through intelligent power source selection.
3Productivity
If the vehicle engine runs continuously to power welding operations, then welding capability is maintained, but vehicle engine life decreases
Solution Approach 1:
The hybrid system implements periodic operation where the engine runs only when necessary to supplement battery power during welding operations, rather than running continuously. This intermittent operation pattern based on actual welding demands significantly reduces cumulative engine runtime and extends engine service life.
Solution Approach 2:
The battery system serves itself by providing power for welding operations without requiring the engine to run continuously. The battery autonomously manages its own discharge and recharge cycles, taking over the welding power provision task and freeing the engine from continuous operation, thereby extending engine life.
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 more efficient and environmentally friendly welding system by reducing emissions and noise, while minimizing fuel consumption, by leveraging the hybrid vehicle's power to support welding operations, enhancing productivity and reducing operational costs.
Implementation Method 1
an engine and an energy storage device adapted to cooperate with electronic circuitry to generate a direct current (DC) bus output
Implementation Method 2
converter circuitry coupled to the engine and the energy storage device and adapted to receive the DC bus output and to convert the DC bus output to a power output appropriate for use by a welding device
Data Source
AI summary
A hybrid vehicle including a welder that is adapted to be powered off a direct current (DC) bus generated by the electronics of the hybrid vehicle is provided. A variety of exemplary placements of the welder on or in the hybrid vehicle are provided. Additionally, a parallel hybrid configuration, a series hybrid configuration, and a series-parallel configuration including welding converter circuitry that is adapted to utilize the DC bus from the hybrid vehicle to generate welding power are provided.