Hybrid Welding Module With Energy Storage Power Boost
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Solution Overview
Problem
Conventional welding power supplies are limited by their rated output, and existing battery-assisted systems require reconfiguration between charging and welding, which is inefficient.
Innovation Solution
A hybrid welding module that charges an energy storage device using welding power from the supply during non-welding operations and supplements the power during welding, allowing the stored energy to boost the available welding power beyond the supply's rated capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional battery-assisted systems are integrated with the welding power supply, then the available power is increased, but the device complexity and reconfiguration requirements increase
Solution Approach 1:
The system is divided into two independent modules: a welding power supply and a hybrid welding module containing the energy storage device. These modules can operate independently or together, eliminating the need for reconfiguration while maintaining power boosting capability. The welding power supply and energy storage device connect through standardized terminals without requiring internal system changes.
Solution Approach 2:
The hybrid welding module is designed to perform multiple functions: it can operate as a standalone energy storage welding system or combine with a welding power supply to provide boosted power. The energy storage device serves both as a power supplement during welding and as an independent power source, eliminating the need for system reconfiguration between different operating modes.
2Use of energy by moving object
If the welding power supply is reconfigured between charging and welding modes, then the energy storage can be utilized, but the productivity and operational efficiency decrease
Solution Approach 1:
The system dynamically switches between charging and welding modes through automated control circuits that monitor operational parameters. The hybrid welding module automatically transitions from charging the energy storage device to discharging it during welding operations without requiring manual reconfiguration, maintaining continuous productivity and operational efficiency.
Solution Approach 2:
The control circuit automatically manages the charging and discharging operations based on detected welding conditions. When welding is detected, the system automatically switches to discharge mode; when welding stops, it automatically switches to charging mode. This self-service operation eliminates manual intervention and maintains high productivity throughout the process.
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 increased welding power output by utilizing stored energy during welding operations, extending the capacity and efficiency of the welding process without the need for reconfiguration.
Implementation Method 1
charges an energy storage device using welding power from the supply during non-welding operations and supplements the power during welding
Data Source
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AI summary
An hybrid welding module is disclosed. Such hybrid welding module includes a welding input switch (108), an energy storage input switch (110), an energy storage output switching circuit (112), and a control circuit (118). The welding input switch (108) receives welding-type input power and selectively outputs the welding-type input power to a weld circuit as first welding-type output power. The energy storage input switch (110) receives the welding-type input power and selectively conducts the welding-type input power to an energy storage device (120). The energy storage output switching circuit (112) converts energy output by the energy storage device (120) to second welding-type power and outputs the second welding-type power to the weld circuit. The control circuit (118) enables charging of the energy storage device (120) by controlling the energy storage input switch (110) to output the welding-type input power to the energy storage device (120), selectively controls the welding input switch (108) to output the welding-type input power to the weld circuit, determines a commanded total welding-type current, monitors a first welding-type current through the welding input switch (108), monitors a second welding-type current output by the energy storage output switching circuit (112), and controls the energy storage output switching circuit (112) to output the second welding-type power for combination with the first welding-type output power based on the commanded total welding-type current, the first welding-type current, and the second welding-type current.