Hybrid Welding Power Supply for Low-Load Engine Switching
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Solution Overview
Problem
Existing hybrid welding systems are inefficient when meeting small weld load demands, as they often activate the engine-generator unit, which is wasteful for low power requirements, and lack a efficient method to manage power distribution between battery and engine-generator units.
Innovation Solution
A hybrid welding system that includes a battery and an engine-generator unit, controlled by a controller to selectively activate the engine only when necessary, using the battery for low power demands and combining both power sources for higher demands, with a charger to recharge the battery during idle periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the engine-generator unit is activated to meet small load demands, then the welding system can provide power for small weld loads, but the system becomes inefficient due to unnecessary engine operation
Solution Approach 1:
The power supply capability is segmented into two distinct sources: a battery for small load demands and an engine-generator for larger demands. This segmentation allows the system to select the appropriate power source based on the specific load requirements, avoiding unnecessary engine operation for small loads while maintaining the ability to handle both small and large welding applications.
2Adaptability or versatility
If a hybrid system with both battery and engine-generator is used, then power management flexibility is improved, but the device complexity increases
Solution Approach 1:
The system merges a battery and an engine-generator into a single hybrid welding power supply unit with integrated control circuitry. The controller automatically manages power distribution between the two sources, combining their capabilities into one cohesive system that provides flexible power management while maintaining a unified device structure.
3Weight of moving object
If the engine is rated below 25 horsepower for portability, then the system remains portable and transportable, but the power output capacity is limited
Solution Approach 1:
The system adds a temporal dimension to power delivery by using the battery to provide supplemental power during high-demand welding operations. The small engine maintains portability while the battery acts as a temporary power reservoir that can be depleted and recharged, effectively increasing the available power capacity without requiring a larger engine.
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 allows for efficient power management, reducing fuel consumption and enabling the system to handle both small and large load requirements without continuous engine-generator operation, maintaining efficiency and portability.
Implementation Method 1
a battery adapted to discharge energy to produce a second power output
Implementation Method 2
an engine adapted to drive a generator to produce a first power output
Implementation Method 3
a charger coupled to the battery and to the engine and adapted to receive power from the engine and to charge the battery with the received power
Data Source
AI summary
Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.