Hybrid Welding Power Supply for Load-Based Battery-Engine Switching
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Solution Overview
Problem
Existing hybrid welding systems are inefficient when meeting small 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 use battery power for low load demands and activate the engine-generator for higher loads, optimizing power output and reducing fuel consumption by using a charger to recharge the battery during lower power demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the engine-generator unit is activated to meet small load demands, then the welding system can provide power output, but fuel consumption increases and efficiency decreases
Solution Approach 1:
The power output range is segmented into multiple thresholds (first threshold and second threshold). The controller divides the operation into different modes: battery-only mode for low power demands, engine-generator mode for medium power demands, and hybrid mode for high power demands. This segmentation allows the system to optimize fuel consumption by selecting the appropriate power source for each load level.
Solution Approach 2:
The system dynamically switches between different power sources and operating modes based on the commanded output level. The controller continuously monitors the load demand and adjusts the power source configuration in real-time, transitioning between battery-only, engine-generator, and hybrid modes as thresholds are crossed. This dynamic adaptation resolves the contradiction by ensuring the engine-generator operates only when necessary.
2Power
If a larger engine is used to handle all load demands, then the system can meet high power requirements, but the system weight and size increase, reducing portability
Solution Approach 1:
The power delivery capability is segmented across two sources: the battery handles low-power demands independently, while the smaller engine-generator handles medium and high-power demands. This segmentation allows the engine to be sized for maximum power requirements without needing to handle all load levels alone, reducing the engine size and associated system weight while maintaining the ability to deliver high power when needed.
Solution Approach 2:
The system merges the battery and engine-generator into a coordinated hybrid power system. The battery provides supplemental power during high-demand operations and standalone power during low-demand operations, allowing the use of a smaller, more portable engine than would be required in a conventional system. This combination resolves the contradiction by achieving high maximum power output without proportionally increasing system weight.
3Reliability
If the engine-generator operates continuously to ensure sufficient power availability, then power reliability is maintained, but energy efficiency deteriorates during low load periods
Solution Approach 1:
The system dynamically adapts its operating mode based on real-time power demands. During low-load periods, the system automatically switches to battery-only mode, eliminating unnecessary engine operation and improving efficiency. During high-load periods or when the battery charge is depleted, the system transitions to engine-generator or hybrid mode to ensure adequate power availability. This dynamic operation resolves the contradiction between reliability and efficiency by matching power source activation to actual needs.
Solution Approach 2:
The controller continuously monitors the commanded output level and battery charge state, using this feedback to determine the appropriate operating mode. The system adjusts its power source selection based on feedback from the load demand and battery status, ensuring reliable power delivery while avoiding inefficient engine operation during low-demand periods. This feedback mechanism enables the system to maintain reliability without continuous engine operation.
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 system efficiently manages power output by using battery power for low demands and engine-generator power for high demands, reducing fuel consumption and maintaining the ability to handle large loads with a smaller engine rating, thus improving 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.